STRALIS AS/AT/AD

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AV

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AN

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STRALIS AS/AT/ADEURO 4/5BODYBUILDERS INSTRUCTIONS

EDITION 2008

Publication Edited by:Technical ApplicationStrada delle Cascinette, 424/3410156 Turin - Italy

Publication Nr. 603.93.721 - 2nd EditionPrinted in Italy - 01/08

B.U. TECHNICAL PUBLISHINGIveco Technical PublicationsLungo Stura Lazio, 15/1910156 Turin - Italy

Produced by:

Print 603.93.721 Base - January 2008

Update data

STRALIS AS/AT/AD EURO 4/5

Bodybuilders instructionsPrint 603.93.721 - 2nd editionBase - January 2008

UPDATE DATA

Section Description Page Revision date

2 Frame Paragraph 2.16 moved to chapter 5 January 2008

3 Structures 3-34: paragraph added 3.5.4.3 January 2008

4 Power take-off Full overhaul chapters 4.6 and 4.7 January 2008

4 Power take-off 4-17: Control unit addedExpansion Module (EM) (*)

January 2008

5 Electronic subsystems 5-4: Cab Module (CM)integrated in the Body Computer (BC) (*)

January 2008

5 Electronic subsystems 5-8,5-9: connectors ST14A e ST14B January 2008

5 Electronic subsystems 5-40: note added to paragraph 5.4.8 January 2008

6 Exhaust systems with SCR Chapters 6.6 and 6.7 added.Full overhaul chapter 6.5

January 2008

(*) Specific parts only for OBD1 Phase 2.

The eighth digit of the PIC (Product Identification Code) indicates STEP 2 of the vehicle:3 - 4 - C - B Stralis AS3 - 4 - C Stralis AT/AD

NOTE

Base - January 2008 Print 603.93.721

Update data

This manual contains instructions and data for fitting body structures/ancillaries and Vehicle modifications and is intended forskilled and qualified personnel.

The bodybuilder is responsible for the design and fitting and any modifications necessary for the installation. The bodybuilder mustensure full compliance with the requirements set out in this manual and with national and international regulations (Constructionand Use, and EEC Standards) in force.

Before starting any work make sure you are working form the latest Iveco Bodybuilders Instruction manual for the model. Make surethat all safety equipment e.g. eye protection, hard hat, shoe, gloves etc are used. Check that all mechanical equipment e.g. lifts andhandling gear is in good working order and is used. Finally work on the vehicle in good conditions and ensure maximum safety atall times.

Any change, modification or installations not covered by this manual and not expressly authorized in writing by IVECO will relievethe latter of any responsibility and make, in particular, the vehicle warranty null and void.

For installations / modifications and general information not covered by this manual contact Iveco.

On completion of the installation e.g. body, crane, wheelbasemodification the vehicle and systemsmust be checked to ensure vehicleoperation and safety is as designed by Iveco and has not been compromised. If a vehicle system needs to be set up i.e. engine controlfor PTO installation then contact your local Iveco Service Department.

IVECO shafl not be responsible for any change, modification or fittings concerning the vehicle.

Due to continuing vehicle improvements and changes in regulations which cover or affect the vehicle, the information in this publica-tion may not always be up to date.

If the bodybuilder has any queries regarding the information contained in this manual regarding the vehicle that is to be worked onhe should contact Iveco [email protected] before starting.

Warning / Precaution:

failure to fully comply with these precautions can result in serious danger to personal safety and damage to the vehiclewith the loss of the vehicle warranty.

Danger of serious damage to the vehicle

Partial or complete non observance of these precautions can cause serious damage to the vehicle and invalidate theIveco warranty.

This indicates the correct use of materials in order to make the vehicle as environmentally friendly as possible.

Danger to people:

failure to fully comply with these precautions can involve serious danger for personal safety.

Symbols - Warnings

!

Foreword

Indicates additional information.NOTE


Foreword

Page header and footer interpretation

Vehicle type Section titleSection number -page number

Printnumber

Chapter title Basic edition -month year


Foreword


Index of section

INDEX OF SECTION

Section

General specifications 1

Chassis modifications 2

Building & Mounting the structures 3

Power Take-offs 4

Special instructions for electronic subsystems 5

Special instructions for -SCR- exhaust system 6


Index of section

GENERAL SPECIFICATIONS 1-1STRALIS AS/AT/AD Euro 4/5


Index

Index

SECTION 1

General specifications

Page

1.1 Aim of bodybuilders instructions 1-3

1.2 IVECO “no objection” for changes and fittings 1-3

1.3 Liabilities 1-4

1.4 Guarantees 1-4

1.5 Request for a “no objection” 1-4

1.6 IVECO technical documents available by means of computer 1-5

1.7 Trademarks and Logos 1-5

1.8 Legal Provisions 1-5

1.9 Prevention of accidents 1-6

1.10 Choice of material to use: Ecology - Recycling 1-6

1.11 Vehicle delivery 1-7

1.12 Vehicles Identification 1-8

1.13 Dimensions and weights 1-9

1.13.1 General Specifications 1-9

1.13.2 Determining the Centre of Gravity of the Body and Payload 1-9

1.13.3 Observing the Permitted Weights 1-13

1.14 Instructions for the Correct Functioning of the Parts of the Vehicle and Accessibility for Maintenance 1-14

1.15 Quality System management 1-15

1.16 Vehicle maintenance 1-15

1.17 Conventions 1-16

1-2 GENERAL SPECIFICATIONS STRALIS AS/AT/AD Euro 4/5


Index



Aim of bodybuilders instructions

Aim of bodybuilders instructions

1.1 Aim of bodybuilders instructions

The purpose of this publication is to provide data, specifications and instructions for the bodybuilding and conversion of an originalIVECO vehicle to ensure the functionality, safety and reliability of the vehicle and its components.

1.2 IVECO “no objection” for changes and fittings

Changes must be carried out in accordance with the requirements set out in the following guidelines.

The followingmay be carried out only with IVECO’s authorisation after submitting a copy (two for English Market) of thedocumenta-tion required for technical evaluation of the proposed change (drawings, calculations, technical report etc.):

- wheelbase modifications, where the new wheelbase does not fall within the minimum and maximum wheelbase available withinthe IVECO range for the same vehicle;

- work carried out on the braking system;

- work carried out on the suspension system;

- steering wheel modifications;

- changes to the stabiliser bars and suspensions;

- changes to the cab, cab supports, locking and tipping devices;

- changes to the intake systems, engine exhaust and SCR components;

- engine cooling system modifications;

- power unit and driving component modifications;

- work carried out on front and rear axles;

- fitting additional axles;

- fitting decelerator brakes;

- fitting power take-offs;

- changing the tyre dimensions;

- coupling device (hooks, fifth wheels) modifications;

- electric/electronic unit modifications.

The other modifications of fittings covered by the following standards and made in compliance with the same do not require specificauthorisation from IVECO.Anymodification or fitting not covered by these standards shall, on the contrary, be authorized by IVECOin advance.



Liabilities

Liabilities

1.3 Liabilities

The authorizations issued by IVECO concern solely the technical/conceptual feasibility of the modification and/or fitting to bemade on a genuine IVECO vehicle.The bodybuilder is responsible for the:

- project of the modification or fitting;

- choice and features of the products used;

- workmanship of the modification or fitting;

- compliance of the project and its implementation with all the instructions provided by IVECO;

- compliance of the project and its implementation with all the current regulations in the country where the vehicle is registered;

- the operation, safety and reliability and in general the effective performance of the vehicle and also the effects that the changesand the conversion may have on the performance and specifications of the vehicle.

1.4 Guarantees

The bodybuilder/chassis converter who has built the body or who has modified the chassis must guarantee that the work wasundertaken in a professional manner in full compliance with the specifications contained in this manual. IVECO reserves the rightto declare void its own warranties for the vehicles where:

- these specifications have not been adhered to or where unauthorised equipment was installed, or unauthorised modificationswere carried out;

- an unsuitable vehicle/model has been used for the required conversion or application;

- the specifications, standards or instructions issued by the Manufacturer for the flawless execution of the operations have notbeen followed;

- original spare parts or components which IVECO has made available for specific conversions were not used.

Maintaining the functionality of vehicle components.The effective operation of vehicle components, all component safety and running conditions, com-pliance with national and international regulations (e.g. EC Directives) and accident prevention stan-dards must be guaranteed in all permitted conversions and applications.All our vehicles are covered by a warranty as laid down in the specific documents.The bodybuilder must carry out operations at least in an equivalent manner.

1.5 Request for a “no objection”

The requests for approval or support to carry out work ormake modifications or fittings shall be forwarded to the IVECOmarke-ting offices in charge.

To obtain the approval, the body builder shall provide adequate documents that illustrate the anticipated implementation, utilizationand conditions of use on the vehicle. The drawings shall highlight any item differing from the instructions contained in this manual.

The body builder shall submit the modification and/or fitting to the competent authorities for approval.



IVECO technical documents available by means of computer

IVECO technical documents available by means of computer

1.6 IVECO technical documents available by means of computer

The following technical documents are available on the Internet at www.thbiveco.com:

- bodybuilder instruction manuals;

- specification sheets;

- chassis cab diagrams in .dwg and tiff formats;

- chassis diagrams in tiff formats;

- other specifications concerning the vehicle range.

1.7 Trademarks and Logos

Trademarks, nameplates and denominations must not be modified or displaced in relation to the original design. The appearanceof the vehicle must not be changed or modified.

The application of trademarks tied to the transformation or trim levels must be authorised by IVECO. They must not be appliednear to the IVECO tradenames or logos.

IVECO reserves the right to withdraw the tradenames and logos if the fitting or conversion fails to conform with requirements. Thebodybuilder accepts all responsibility for the entire vehicle.

Instruction for added assemblies

Where assemblies are added, the bodybuildermust provide the necessary service andmaintenance instructions when the vehicleis delivered.

1.8 Legal Provisions

On completing the vehicle, the bodybuilder/chassis converter must check the work (modifications, body + equipment etc.) toensure that the legal provisions required in the country of registration are observed (e.g. weights, dimensions, braking, noise,emissions etc.). Information regarding these matters may be obtained from the competent Authorities or the IVECOAreaNetwork.

The vehiclesmanufactured at our plant (except some versions for Extra-European countries) comply with the EC directives. Conver-ted vehicles must also comply with these directives. The only permissible exception is granted where local type approval differs fromEC homologation.



Prevention of accidents

Prevention of accidents

1.9 Prevention of accidents

The structures and devices fitted to the vehiclesmust complywith the current regulations concerningthe prevention of accidents and safety regulations in force in the countries where the vehicle is to beused.

All the precautions dictated by technical awareness must be adopted to prevent malfunction and functional defects.Compliance with these regulations will be the responsibility of the manufacturers of the structures and devices.

!Components suchas seats, coverings, linings, protective panels etc.maypresent apotential fire hazardif they are exposed to an intense heat source.

They should be removed before working with welding equipment and flames.

1.10 Choice of material to use: Ecology - Recycling

Increasingly greater attention should be paid, at the study and design stage, to the choice of materials to be used.

This is especially the case as regards the aspects connected with ecology and recycling in the light of domestic and internationalregulations that are constantly being developed in the sector.

In this connection:

- everyonemust be aware of the prohibitions on using harmful or potentially hazardousmaterials, such as ones containing asbestos,lead, halogen additives, fluorocarbons, cadmium, mercury, hexavalent chrome, etc.

- Use materials whose processing produces limited waste and that permit easy recycling after their first use.

- With composite synthetic materials, use components that are compatible with each other, envisaging also their possible utiliz-ation with the addition of other salvaged components. Affix the markings required in compliance with the current regulations.

In order to comply with EC directive 2000/53 (ELVs), IVECO S.p.A. prohibits fitting parts containinglead, mercury, cadmium and hexavalent chrome to vehicles (except for the departures referred to inAttachment II of the above directive).



Vehicle delivery

Vehicle delivery

1.11 Vehicle delivery

Prior to delivering the vehicle, the body builder shall:

- verify that the work has been made correctly;

- perform vehicle and/or equipment set-up;

- check the operation and safety of the vehicle and/or equipment;

- prepare and deliver the necessary instructions for service andmaintenance of the fitting and any additional units to the end custo-mer;

- write the new data down on the special tags;

- confirm that the work carried out complies with the indications provided by the vehicle manufacturer and with all legal require-ments;

- carry out the checks included in the ”IVECO Pre-Delivery inspection” list (available from the IVECO network) with regard tothe items affected by the work done;

- provide a guarantee for the modifications made;

- in the event that the connections originally provided with screws have been mounted and restored, the same screws must notbe used. In such an instance, and in the event that rivets have been replaced with screws, you must again check the tightnessof the connection after travelling approximately 500-1000 km, to ensure it is to the correct torque.

- measure the battery voltage. Ensure there is a minimum charge of 12.5 V. If the voltage reading is between 12.1 and 12.49 V,recharge the battery (slow charge). If the voltage is less than 12.1 V, the battery must be scrapped and replaced with a new one.



Vehicles identification

Vehicles identification

1.12 Vehicles identification

The commercial designation of IVECO vehicles is not the same as the type approval (homologation) designation. Two typesof commercial designation are shown below with the meaning of the codes used:

CabRange

Model Power Version Suspension

CAB VERSIONS

TRACTOR

A S 2 6 0 / P SS 24

A S 4 4 0 / PS 54 XT

AS

AD

AT

PTT-Cab versions(n˚/10→ hung in ton)

PTC-Tractors(with semitrailers)

(n˚/10→ hung in ton)

STRALIS Engine power

(n˚ x 10→ HP)

T

XYZ

/TN/P/PT/PS/FP

/FS

EXTERNAL NAMEPLATE ONVEHICLE

CAB RANGE

AS = Active SpaceAT = Active TimeAD = Active Day

VERSION

T = TractorX = 6x2CY = 6x2P(Z= 6x4)

SUSPENSION

/TN = 6x2P, mechanics with third fixed axle to twinned wheels/P = 4x2, 6x4, 6x2P, air suspension at rear. 6x2P with single wheels fixed third axle/PT = Only for 6x2P, air suspension at rear with twin wheels fixed third axle/PS = Only for 6x2P, air suspension at rear with single wheels third axle, controlled steering/FP = 4x2, 6x4, 6x2P, full air/FS = Only for 6x2P full air with single wheels third axle, controlled steering

MISSION

GV = Bulky Goodstransport

CM = Mobile BoxesLT = Low TractorRR = Rough RoadsHM = Heavy MissionD = DeliveryCT = With TransporterHR = Hub Reduction

Y



Dimensions and weights


1.13 Dimensions and weights

1.13.1 General Specifications

The dimensions and maximum permissible weight on the axles are indicated on drawings, on technical specifications and, ingreater details, on the official documentation issued by IVECO.

The kerb weights refer to vehicles with standard equipment. Special equipment may involve considerable modification to the weightand its distribution on the axles.

Lights and rear-view mirrors positioning on our vehicles is designed for widths of 2,550 mm. This dimension may also be appliedto special body versions with a width of 2,600 mm (e.g. refrigerator vans).

Weighing the Chassis

As a result of production factors there may be a variation in weight of approx. 5%.

It is, therefore, advisable to determine the weight of the vehicle with its cab before fitting the body and equipment and establishingtheir distribution on the axles.

1.13.2 Determining the Centre of Gravity of the Body and Payload

Positioning on longitudinal plane

To establish the location of the centre of gravity of the body and payload the following examples belowmay be used as guidelines.

The technical documentation specific to eachmodel (chassis cab drawing) give the positions permittedwith the vehicle in its standardform. The weight and positioning of the single components of the vehicle are given in the chassis and weight distribution diagram.




Figure 1.1 Vehicles with 2 axles; vehicles with 3 axles with an equal load on the tworear axles

A = Rear axle or tandem mid axleW = Payload + bodyW1 = Share of payload on front axleW2 = Share of payload on rear axle (or tandem)

L1 = Distance of centre of gravity fromcentre-line of rear axle(or tandem centre-line)

L = Actual wheelbase

Example to determine the position of the centre of gravity of the payload plus body

L1 =W1 ⋅ L

W

respectively L1 = L -W2 ⋅ L

W

Figure 1.2

W = Payload + bodyW1 = Share of payload on front axleW2 = Share of payload on rear axlesW3 = Share of payload on first rear axleW4 = Share of payload on second rear axleL1 = Distance of centre of gravity relative

calculated centrelineL = Calculated wheelbase (ideal)L2 = Calculated centreline (ideal)A = Distance between rear axles

Attention:On vehicles with three or more axles, with a variable mass distributionratio on the two rear axles depending on the load, the ”ideal” values ofwheelbase and centreline between the axles will have to be calculatedon the basis of the information given in the chassis cab diagram, or in thespecific documentation specially prepared by IVECO. In this way, forspecial versions (e.g. cranes on rear overhang) itwill be possible todeter-mine the correct positioning of the centre of gravity of the equipmentand payload on the basis of the actual load (see point 5.4 in section 5).

Example to verify compliance of admitted weight on the axles

Vehicles with 3 or more axles with a constant mass distribution ratio onthe two rear axles. For these vehicles the ”ideal” values of thewheelbaseand centreline between the axles, resulting frommass distribution, is de-termined by the Manufacturer.

W1 =W x L1L

W2 = W x(L - L1)

L

W3 = W2 x(A - L2)

A

W4 =W2 x L2A




In order to apportion the payload on the axles, it must be uniformly distributed except when the shape of the loading surface itselfentails a different distribution of the load.

As for equipment, the actual location of the centre of gravity is used.

When building bodies or containers, loading and unloading systems for the transported goods must be devised which preclude ex-cessive variations in the distribution of the load and/or excessive loads on the axles, also giving the relevant instructions to the users.

The bodybuilder will also need to install suitable payload securing systems on the body so that transport can be madewith the utmostsafety.

Uniform distribution of the load Non-uniform distribution of the load due to thelack of rear overhang

Uniform distribution of the load Non-uniform distribution of th e load (beware of load on axlesand minimum ratio)

Figure 1.3




Height of the Centre of Gravity

The height of the centre of gravity of the chassis cab is given in the technical documentation specific to each model (chassisdrawing).

For testing the vehicle complete with superstructure, the bodybuilder must check that the height of the centre of gravity of theequipment including the payload, or of the entire vehicle when fully loaded, falls within the maximum permitted values.

These limits are defined in compliance with the national or international regulations (e.g. as amended by the current EC brakingDirective) or requested by the Manufacturer to ensure good handling of the vehicle (e.g. transverse stability of the moving vehicle).

In order to comply with the current ECDirective, IVECO provides information for the variousmodels (wheelbase and specific body)on computer, regarding:

- height of centre of gravity of chassis cab (e.g. chassis cab diagram, braking data);

- maximum height of centre of gravity of complete vehicle at full load (e.g. national type-approval document);

- braking capacity of each single axle (e.g. braking data).

Figure 1.4

Verification with full load:

Wv = Chassis cab vehicle kerb weightHv = Height of centre of gravity of chassis cab vehicle (laden condition)Ws = Body and payloadHs = Height of centre of gravity of body and payload in relation to groundWt = Vehicle weight when fully loadedHt = Height of centre of gravity of vehicle fully laden to gvw

Ht=Wv . Hv + Ws . HsWv + Ws

Hs= (Wv + Ws) . Ht − Wv . Hv

Ws

To check the vehicle with its body but no payload, use above formula but for Ws use only the body kerb weight (The position forHv will depend on the load and deflection of the suspension).

The height of the centre of gravity indicated in Tabella 2.6 represents values which are not to be exceeded for each given equipmentlevel. These values have been calculated only in terms of the transverse stability of the vehicle and are applicable to a mid wheelbase.Any other possible restrictive specification, e.g. braking regulation, should be taken into consideration.

The values given in Tabella 2.6 refer to the superstructure with fixed payload. In versions where the payload tends to move on side(e.g. suspended loads, fluid loads etc.) especially when turning, higher dynamic stress is generated which makes the vehicle less stable.This must be taken into consideration when providing vehicle operating instructions or for possible reduction in the height of thecentre of gravity.




Using Stabiliser BarsSupplementary stabilising or anti-roll bars, where available, spring reinforcements or the application of rubber components (in

compliance with point 2.7) may increase the height of the centre of gravity of the payload which must be defined as each occasionarises. The modification must be carried out after careful consideration has been given to the specifications of the version, to thewheelbase and to the distribution of the cross-stresses acting on the suspension both at the front and at the rear of the vehicle.It must be borne in mind that it is often advisable to modify the rear axle only since a modified front axle would give the driver afalse sense of stability making it more difficult to perceive the safety limits. Modification to the front axle may be made where theload is positioned behind the cab (e.g. crane) or where the superstructures are very rigid (e.g. van conversion).

Exceeding the LimitsWhen transporting goodswith an exceptionally high centre of gravity (e.g. machinery, indivisible cargo etc.) from a technical point

of view it is possible to exceed the values indicated in the table provided that the steering system of the vehicle is suitably adaptedto this condition (e.g. reduced speed, gradual changes on the steering wheel, etc.).

1.13.3 Observing the Permitted Weights

All limits indicated in our documentation must be adhered to. The load of the front axle is of particular importance under varyingload conditions, in order to ensure the correct steering characteristics on road surfaces of all types.

Particular attention must therefore be paid to vehicles with a weight which is concentrated on the rear overhang (e.g. cranes, tail-lifts,centre axle trailers) and to vehicles with a short wheelbase and a high centre of gravity (e.g. silo vehicles, cement mixers).

When positioning the body and equipment, the loads must be correctly distributed transversally. For each wheel a variation in therated load (1/2 of the axial load) of 4% is permitted (e.g. admitted load on axle: 10,000 kg load admitted on each wheel: 4,800 to5,200 kg) provided that the tyres permit it, without impairing braking or driving stability.

For vehicles with an added rear lift axle it must be remembered that, with the axle in the raised position, the effective wheelbaseis reduced, whereas the rear overhang is increased. It is therefore advisable that the centre of gravity of the body and payload islocated in front of the centre line of the driving axle. In addition to this it is not advisable to equip a vehicle which has its load concen-trated at the rear, with a lifting device.Apart from different specifications for specific individual vehicles, the following may be taken to be the minimum values for the frontaxle:

- 20% of the total vehicle weight with uniformly distributed loads

- 25% of the total vehicle weight for loads that are concentrated on the rear overhang.

The rear overhang of the body must be built in strict observance of the permitted axle loads, the limitations in length, the positioningof the tow hook and of the underride guard stipulated by the relevant regulations and legal requirements.

Variations in the Permissible weightSpecial exceptions to the maximum permissible weight may be granted for particular applications for which, however, precise

limitations regarding the use will be imposed in addition to possible vehicle reinforcements.

Such exemptions, if they exceed the limits imposed by law, must be authorised by the Administrative Authority.

A reduction in admissible vehicle load (downrating) may require modifications on some parts, such as the suspension. In these cir-cumstances, the necessary information may be supplied.

The request for authorisation must include:

- Vehicle type, wheelbase, identification number, designated use.

- Weight distribution on the axles (e.g. vehicles equipped with crane and body) including positions of the centre of gravity of thepayload.

- Proposals concerning the reinforcement of the vehicle components where necessary.



Instructions for the Correct Functioning of the Parts of the Vehicle and Accessibility for Maintenance


1.14 Instructions for the Correct Functioning of the Parts of the Vehicleand Accessibility for Maintenance

As a rule, when modifying or installing any type of equipment, nothing must be altered which prevents the correct functioningof assemblies and parts of the vehicle under all operational conditions.

For example:

- Ready access to all parts requiring inspection or maintenance and periodic servicing must be provided. In the case of closed bodytypes suitable opening doors must be provided.

- For tilting cabs, adequate space permitting tilting must be assured. In the case of structures which involve the space above thedriver’s cab, adequate space for the passage of intake air must be guaranteed (see 1.5).

Figure 1.5

1. Retain adequate room for tilting the driver’s cab - 2. Retain the free space above the gearbox (for tractors with semitrailersconsider the movement between tractor and semitrailer) - 3. Cab pivot point - 4. Min. distance to be met

- Service access to chassis/driveline components must be retained. For instance repairing the gearbox or clutch must be possiblewithout necessitating the removal of major components of the added structure.

- The cooling system (radiator cowling, radiator, air passages, cooling circuit etc.), fuel supply (pump position, filters, pipe diameter,etc.) and the engine air intake must not be altered.

- The anti-noise panels must not be altered or moved in order to prevent changes in the approved noise levels of the vehicle.Should it be necessary to make openings (e.g. for the longitudinal runner of the body to pass through) these must be properlyclosed off using material with inflammability and soundproofing characteristics equivalent to those used originally.




- Adequate ventilation of the brakes and battery case (especially in the case of box bodies) must be guaranteed.

- The positioning of the mud-guards and wheel-arches must allow free movement of the rear wheels even when chains are beingused. Sufficient space must also be ensured with lifting axles. Some of our models have 3rd axle steering which also steers inthe raised position; and it is necessary to leave space for this function (see point 2.20).

- When the vehicle has been set up, for safety reasons, headlight attitude must be checked and adjusted as necessary. Performthe adjustment according to the instructions provided in the user and maintenance manual.

- In the case of parts which are supplied loose (e.g. spare wheel, chocks) it will be the responsibility of the bodybuilder to positionand secure them in an accessible and safe manner in compliance with possible national regulations.

1.15 Quality System management

For some time IVECO has been promoting Quality System development and training for bodybuilders.

This is a requirement due not only to compliancewith domestic and international regulations on product liability, but also the growingdemand for increasingly higher quality levels. The creation of new forms of organization in the various sectors and the quest forincreasingly more advanced levels of efficiency.

IVECO believes it essential for bodybuilders to be equipped and organised where the following are defined and available:

- organization charts for functions and responsibilities.

- Quality System.

- quality goals.

- technical design documentation.

- process and control phases with relevant resources.

- product improvement plan, obtained also with corrective actions.

- after sales service.

- staff training.

- manufacturer liability documentation.

1.16 Vehicle maintenance

In addition to making the necessary checks on the body/structure in keeping with customary working procedures, the bodybuil-der shall perform the checks specified in the “IVECO pre-delivery inspection” list, which can be obtained from the IVECO network,for the aspects affected by the modifications performed.



Convention

Convention

1.17 Conventions

In these bodybuilders instructions, the wheelbase is taken as the distance between the centreline of the first steering axle andthe centreline of the first rear axle (driven or non-driven). This definition differs from the definition of wheelbase in the CEDirectives.The rear overhang is taken as the distance between centreline of the last axle and the rear end of the chassis runner. For dimensionsA, B and t of the frame and subframe section please refer to the figure below.

Figure 1.6

91473

CHASSIS MODIFICATIONS 2-1STRALIS AS/AT/AD Euro 4/5


Index

Index

SECTION 2

Chassis modifications

Page

2.1 General instructions for chassis modifications 2-5

2.1.1 Specific Precautions 2-5

2.2 Painting and Rust Protection 2-7

2.2.1 Original components 2-7

2.2.2 Added or modified painted parts 2-9

2.2.3 Precautions 2-10

2.2.4 Max indicative height of center of gravity of payload in relation to transverse stability 2-11

2.3 Drilling the Chassis 2-12

2.3.1 Screws and nuts 2-12

2.3.2 Characteristics of the material to be used when modifying the chassis 2-13

2.3.3 Stresses on the chassis 2-14

2.3.4 Welding the Chassis 2-15

2.3.5 Closing of existing holes 2-17

2.4 Modifying the Wheelbase 2-18


2.4.2 Authorisation 2-18

2.4.3 Effects on the steering 2-18

2.4.4 Effects on braking 2-19

2.4.5 Recommended procedure 2-19

2.4.6 Chassis Stress Level 2-20

2.4.7 Cross Members 2-20

2.4.8 Changes to transmissions 2-20

2.5 Modifying the Rear Overhang 2-21


2.5.2 Reducing the Overhang 2-21

2.5.3 Increasing the Overhang 2-21

2.6 Installing a Towing Device 2-23

2-2 CHASSIS MODIFICATIONS STRALIS AS/AT/AD Euro 4/5


Index

Page


2.6.2 Traditional towing hooks 2-24

2.6.3 Towhook for mid-axled trailers 2-25

2.6.4 Lowered Rear Cross Member 2-27

2.6.4.1 Centre axle trailers: towing cross member in lowered and forward positions (short coupling) 2-35

2.6.4.2 Reinforcement of Standard Rear Cross Member 2-35

2.6.4.3 Tow hooks for Centre Axle Trailers 2-37

2.6.4.4 Remarks about the Payload 2-37

2.6.4.5 Increasing the Towable weight 2-38

2.7 Installing a Supplementary Axle 2-38


2.7.2 Chassis Frame Reinforcement 2-38

2.7.3 Installing a Rear Supplementary Axle 2-40

2.7.4 Steering Axles 2-41

2.7.5 Components and Suspension 2-41

2.7.6 Stabilisers 2-41

2.7.7 Connection to the Chassis Frame 2-41

2.7.8 Braking system for additional axle 2-42

2.7.9 Raise Device 2-42

2.7.10 Modifying the suspension 2-45

2.8 Modifying the Drive Line 2-43

2.8.1 Permitted lengths 2-44

2.8.2 Determining Driveshaft Positions 2-46

2.9 Modifications of the Engine Air Intake and Exhaust Syatem 2-49

2.9.1 Intake 2-49

2.9.2 Engine exhaust 2-49

2.10 Modification of the Engine Cooling System 2-50

2.11 Installation of a Supplementary Heating System 2-51

2.12 Installing an Air-Conditioning System 2-52



Index

Page

2.13 Cab Modifications 2-53


2.13.2 Roof Panel Modifications 2-53

2.14 Changing the Size of the Tyres 2-54

2.15 Modifications to the Braking System 2-56


2.15.2 Brake Pipes 2-56

2.15.3 Electronic braking system control devices 2-61

2.15.4 Taking air from the system 2-61

2.16 Electrical System: Modifications and Drawing-Off Power 2-62

2.17 Repositioning Parts and Mounting Auxiliary Assemblies and Equipment 2-62

2.18 Transporting hazardous goods ADR 2-65

2.19 Retarder installation 2-67

2.20 Modifications to the Rear Underrun 2-68

2.21 Rear Mudguards and Wheel Boxes 2-69

2.22 Mudflaps 2-70

2.23 Side Guards 2.71

2.24 Chocks 2-73



Index



General instructions for chassis modifications

2222.2


2.1 General instructions for chassis modifications

Particular attention must be given to the following points:

- Welding to the bearing structures of the chassis is explicitly prohibited (with the exception of the items described at points2.3.4, 2.4 e 2.5).

- Holes in the flanges of the side members are not permitted (except for the items described at point 3.4).

- Where riveted connections exist and can be modified as explained below, these can be replaced by flanged-head screws andnuts of min. class 8.8 or by hex screws of the next greater diameter and self locking nuts. Screws greater than M14 must notbe used (max. diameter of hole 15 mm) unless otherwise specified.

- In cases where the original joints were detached and rejoined with bolts it is forbidden to reuse the same bolts. In this eventand when rivets are replaced with bolts, the bolt torque must be checked after the vehicle has been driven approximately 500÷ 1.000 kms.

2.1.1 Specific Precautions

!Duringwelding, drilling, grinding and cutting operations near brake systempipes, and electri-cal cables, adopt the appropriate precautions for their protection. Remove them altogetherif necessary (observe the requirements set out under points 2.15.2 and 5.5).

Figure 2.1

91444




Take precautions concerning the alternator and the electrical/electronic components

In order to avoid damaging the diode rectifier, never disconnect the batteries (or open the isolator) when the engine is running.If the vehicle has to be tow started make certain that the batteries are connected. Should it be necessary to charge the batteries,disconnect them from the vehicle circuit.In order to run the engine with external means and in order to avoid current peaks which might damage the electric/electroniccomponents, do not use the ”start” function in conjunction with external charge devices if such devices are equipped with thisfunction. Starting will have to be carried out only with the external battery trolley ensuring correct polarity.

Earth connections

As a general rule the original earth connections of the vehicle must not be changed. If it is necessary to move these connectionsor to implement further earth points use the existing holes on the chassis as far as possible and:

- Remove, mechanically, and/or with an appropriate chemical product, the paint on the chassis side and on the terminal side creat-ing a resting plane free from indentations or ridges.

- Apply appropriate high conductivity paint between the cable terminal and the metal surface (e.g. galvanizing paint IVECO Partnumber 459622 by PPG).

- Connect the earth cables within 5 minutes from the application of the paint.

Do not use the IVECO standardised M1 (battery earth connection) M2, M8 (earth connection for started motor depending on thedriving position) points for the earth connections for control switches (e.g. sensor or low absorption devices).

With regard to the electronic devices, avoid linking earth connections between the devices; only use singlewire earths with optimisedlengths (as short as possible).

Electric wiring

!Stralis vehicles are equipped with an innovative electronic system calledMUX. Before performing anyoperation on the electrical system, read section 5 “Special instructions for electronic subsystems”.

For further information regarding the braking and electronic system, refer to point 2.15 and 5.5.

List of technical guidelines and standards for correct installation of electrical cables in vehicle electronic systems

Power cables (+ direct type) must be fed on their own into corrugated piping (of appropriate diameter) and not together with othersmaller cables (signal and negative cables); they must be spaced a minimum distance of 100 mm apart (reference value = 150 mm)from high heat sources (engine turbine, exhaust manifold, etc., ...). and a distance of at least 50 mmmust bemaintained from chemicalagent containers (batteries, etc.).

This rule also applies to the area around moving parts.

Cables that run through perforated or angled panels must be protected by screw-on adaptors for cables (in addition to the corru-gated pipe).

The corrugated pipe must wrap fully around the entire cable and must be secured with a heat-shrink sleeve or using adhesive tapeto the plastic terminal caps. Collars securing the corrugated pipe cut along their length must not deform the pipe, otherwise thecables could be laid bare or come into contact with the sharp corners of the corrugated pipe.

All connection terminals (+) of the above cables and also their terminals must be covered with plastic caps waterproof version, atall points exposed to atmospheric ingress or where water builds up.

The fastening of the terminal on the clamps (including the earth clamps) must be protected against accidental loosening. For thisreason, it is necessary to apply an appropriate tightening torque if possible. In the case of multiple terminal connections, these mustbe in a star configuration (but this connection method should be avoided if possible).

The relevant cable route must be supported by fastenings and collars spaced close together to prevent hanging cables. After repair,outfitting or conversion work, restore the wiring harness to its original condition.

When connecting the frame and the tipper cab, check the wiring with the cab raised and tipped to detect and correct any abrasionsor tautness of the cables.



Painting and Rust Protection


2.2 Painting and Rust Protection

2.2.1 Original components

Table 2.1 shows the protection and painting classes required for original vehicle components. Table 2.2 shows classes for unpain-ted or aluminium parts and Table 2.3 shows classes for painted parts.

Table 2.1 - Protection classes as for STD 18 - 1600 (Schedule I)

Class Features of the part Examples of the type of part

A Parts in direct contact with atmospheric agents Cab, rear view mirrors, cab fixing components

B Parts in direct contact with atmospheric agents withmostly structural characteristics directly visible

Chassis and related parts, including fixing. Componentsand parts under the hood

B1mostly structural characteristics, directly visible

Rear and front axles

CParts in direct contact with atmospheric agents, notdirectly visible

Engine and related parts

D Parts not in direct contact with atmospheric agents Pedals, seat frames, fixing components, internal cab pillars

Table 2.2 - Various unpainted and/or aluminium parts and components

Material Type of protectionClass

Material Type of protectionA B - B1 C D

Stainlesssteel

- yes - - -

chemical coatingDAC 500/8/PLGEO 321/8/PL (*)GEO 321/8/PM (*)

(1)DAC 320/5GEO 321/5 (*)GEO 500/5 (*)

(1)---

---

FE/ZN 12 III - - yes yesFerrous FE/ZN 12 IV (*) - - yes yes( )

Zinc treatment (2)-

FE/ZN 12 V( )

- yes - -

FE/ZN 12 IV S (*) -

yyes - -

AluminiumAnodizing yes yes yes yes

AluminiumPainting yes - - -

(*) Hexavalent chromium-free

(1) I.S. 18-1101

(2) I.S. 18-1102




Table 2.3 - Painted parts as for STD 18 - 1600 (Schedule III)

Description of the cycle phaseClasses

Description of the cycle phaseA B (5) B1 C D

Mechanical surface cleaning (including Sand blasting - yes • - yes • yes •Mechanical surface cleaning (includingthe removal of burrs / rust and cleaningf d f d )

Brushing yes •gof modified parts) Sanding

Degreasing - - - yes • yes •

Pre treatmentPhosphate degreasing

Pre-treatmentPhosphating of the heavy iron yes •Phosphating of the zinc yes

Cataphoretic treatment

High thickness (30-40 μm) yes (1) yes (4)•

- yes (6)•

yes •

Cataphoretic treatment Low thickness (15-25 μm) yes (2)Acrylic to finish (>35 μm) -

Anti rustBicomponent (30-40 μm) - yes (7) -

Anti-rustMonocomponent (30-40 μm) - yes

Chip-resistant baseMono (130 °C) or bicomponent (30-40μm)

yes (2) - - - -

Mono (130 °C) or bicomponent (30-40μm)

yes yes • - yes • yes •

Paint Powders (50-60 μm) yes (3) yesMonocomponent at low temperature(30-40 μm)

- - yes

(1) = Cycle for two-coat preparation.(2) = Cycle for three-coat preparation.(3) = Alternative to the mono or bicomponent paint, only for cab parts (windscreen wipers, rear view mirrors, etc.)(4) = Excluding parts that cannot be immersed in pre-treatment and paint baths, due to their geometry (air tanks), their large size (castings) orwhere thiswould

compromise their functionality (mechanical parts).(5) = For ferrous steel or pre-coated fuel tanks, refer to Table 2.2.(6) = Only parts fitted on the engine.(7) = Parts that cannot be treated cataphoretically (4).• = Alternative products and cycles for the same class, as long as they are compatible with the part being treated.

All components installed on chassis must be painted as per Sta Iveco 18-1600Colour IC444RAL 7021brightness 70/80 gloss.

NOTE




2.2.2 Added or modified painted parts

All parts of the vehicle (cab, chassis, bodywork, etc.) which are added or subjected to modification must be protected from rustand corrosion.

There must be no unprotected areas on ferrous materials.

Table 2.4 (painted) and Table 2.5 (unpainted) show the minimum treatments required for modified or added components whenit is not possible to provide the same protection as that used on IVECO original components. Different treatments are allowedon condition that the same level of protection against rust and corrosion is guaranteed.

Never use powder enamels directly after degreasing.

Parts in light alloy, brass and copper must not be protected.

Table 2.4 - Added or modified painted parts

Description of the cycle phaseClass

Description of the cycle phaseA - B - D (1)

Mechanical surface cleaning (including the removal of burrs / rustMechanical surface cleaning (including the removal of burrs / rustand cleaning of modified parts)

Brushing/sanding/sand blastingand cleaning of modified parts)

Brushing/sanding/sand blasting

Pre-treatment Degreasing

Anti-rust Bicomponent (30-40μm) (2)

Paint Bicomponent (30-40μm) (3)

(1) = Modifications to rear axles, front axles and engine (Classes B1 and C) are not allowed.(2) = Preferably epoxy.(3) = Preferably polyurethane.

Table 2.5 - Added or modified unpainted and/or aluminium parts

Material Type of protectionClass

Material Type of protectionA - B (1) D

Stainless steelyes

-

Ferrouschemical coating

yes-

FerrousZinc treatment - yes

AluminiumAnodizing yes yes

AluminiumPainting - -

(1) = Modifications to rear axles, front axles and engine (Classes B1 and C) are not allowed.




2.2.3 Precautions

Suitable precautions must be taken to protect those parts whose preservation and operation could be damaged by paints suchas:

- rubber or plastic pipes for the air and hydraulic installations;

- gaskets, parts in rubber or plastic;

- flanges of the transmission shafts or power take-offs;

- radiators;

- shock absorber and hydraulic or air cylinder rods;

- drainage and bleeder valves (mechanical components, air tanks, cold starting heater plug pre-heating tanks etc.);

- fuel sediment filter;

- nameplates and logos.

With particular regard to the engine and its electric and electronic components, adequate precautions must be taken to protect:

- on the whole engine and vehicle wiring, including earth contacts;

- on all connectors on sensor/actuator side and wiring side;

- on all sensors/actuators, on flywheel, on flywheel rev sensor bracket;

- on the whole diesel fuel system pipes (plastic and metallic);

- on complete diesel fuel filter base;

- on control unit and control unit base;

- on the whole soundproofing cover inner side (injectors, rail, pipes);

- on common rail pump including regulator;

- on vehicle electric pump;

- on tank;

- on front belt circuit and relevant pulleys;

- on power steering pump and relevant piping;

- ECU’s fitted on the vehicle.

If the wheels are removed, protect the contact surfaces on the hubs, avoid increasing the thickness and especially avoid the build-upof paint on the connecting flanges of the wheel disks and contact points of the fixing nuts.

Ensure that the disc brakes are adequately protected.

The electronic components and modules must be removed.

!When the painting operation is to be completedby ovendrying (max. temp. 80ºC), all parts whichmaybe damaged by exposure to heat, must be removed.




2.2.4 Max indicative height of center of gravity of payload in relation to transverse stability 1)

Table 2.6

M d l

Base equipmentwith anti roll bars Max indicative height of center of gravity

(including body or equipment) in relation toModelsFront Rear

(including body or equipment) in relation tothe ground (mm)

1 2 1 2the ground (mm)

AS/AD/AT 190 x x 2720

AS/AD/AT 190/P x x 2750

AS/AD/AT 260 Y/TN x x 2740

AS/AD/AT 260 Y/P, Y/PS x x x 2720

AS/AD/AT 260Z/P x x x 2830

AS/AD/AT 260/P x x x 2720

Notes:1) = Values refer to the transverse stability of the vehicle, to hold present eventual other limitations takes from the national and international regulations in

force (es. braking)x = with standard anti-roll bar- = without anti-roll barSW = to request roll bar



Drilling the Chassis


2.3 Drilling the Chassis

When it is necessary to mount assemblies or auxiliary units on the chassis, as a general rule, the existing holes made at the factoryshould be used.Under no circumstances should the flanges of the supporting member of the vehicle be drilled unless in compliance with

the indications given in point 3.3.1.

In those cases (installation of shelves, brackets etc.) where it is necessary to drill new holes, they must be drilled on the verticalweb of the side member and must be carefully deburred and reamed.

Position and Size

The new holes must not be made in areas of high stress (such as supports for springs) and at variance with the cross-sectionof the side member.

The diameter of the holes must be proportional to the thickness of the steel. Under no circumstances must this exceed 15 mmunless otherwise specified. The distance from the centre of the hole to the edges of the side member must not be below 40 mm.The centres of the holes must never be located at a distance of less than 45 mm from each other or in relation to the existing holes.The holes must be staggered as shown in Figure 2.2. When moving spring support or crossmembers, the same drilling arrangementmust be used always maintain the original boring.

Figure 2.2

91445

2.3.1 Screws and nuts

In general, use connectors of the same type and class as those for similar fixings on the original vehicle (Table 2.7).

As a general rule, materials of class 8.8 are recommended. Class 8.8 and 10.9 screws must have been hardened and tempered. Forapplications of diameter ± 6mm, stainless steel parts are recommended. Approved finishes are Dacromet and zinc coating, as detailedin Table 2.2. A Dacromet finish is not recommended if the screws are to be subjected to welding. If space allows, use screws andnuts with flanged heads. Use self-locking nuts. Nuts must be tightened using a torque wrench set to the correct torque setting forthe fixing.




Table 2.7 - Classes of resistance for screws

Class of resistance Usage Tensile strength(N/mm2)

Yield point(N/mm2)

4 (1) Non-load bearing screws 400 320

5.8 (1) Low resistance screws 500 400

8.8Medium resistance screws

(cross members, cleat plates,brackets)

800 640

10.9High resistance screws

(spring supports, anti-roll barsand shock absorbers)

1000 900

(*) Do not use

2.3.2 Characteristics of the material to be used when modifying the chassis

When modifying the chassis of the vehicle, and in applications which reinforce the side members directly, the material used mustcorrespond in quality (Table 2.8) and thickness (Table 2.9) to that of the original chassis.

Should it not be possible to source materials of the thickness indicated, the next greater thickness may be used (e.g. 1 mm insteadof 6.1 mm).

Table 2.8 - Material to be used to modify the chassis

Steel name Tensile strength(N/mm2)

Yield point(N/mm2) A5 elongation

IVECO FeE490

Europe S500MC 610 490 19%

Germany QStE500TM

Alternatively, just for rear overhang extension.

IVECO Fe510D

Europe S355J2G3520 360 22%

Germany QSt52-3N520 360 22%

UK BS50D




Table 2.9 - Chassis section dimension and thickness

Model Wheelbase (mm) AxBxt longitudinal pitchsection(See Figure 1.6)

AD/AT/AS 190 Up to 6300 289/199x80x6,7

AS260/FP/FS Up to 5100+1395 289/199x80x6,7

AS260 S/PT Only 5700, 6050 289x80x7.7

AS260 (6X4) 4500 289x80x7.7

IVECO recommends the following chassis extension pieces, available from the Spare Part Division are used for chassis extensions.

2.3.3 Stresses on the chassis

Do not exceed the following stress values under static conditions:

Table 2.10

Range Permitted static stress on the chassis (N/mm2) σ amm.

On road Off-road use

Stralis 150 100

When required by national regulations, the bodybuilder must check that the stress limits are not exceeded.

Welding activity will cause a deterioration in the characteristics of the material. Therefore, when checking the stresses in thermically-modified zones, consider a reduction of approx. 15% of the resistance characteristics.




2.3.4 Welding the Chassis

!Welding operationsmust only be carried out by specialist, trained personnel, using suitable equipmentand in a perfectlyworkmanlikemanner. Any intervention on the system not carried out as per instruc-tions provided by IVECO or carried out by unskilled staff, might severely damage the on-board sys-tems, thus adversely affecting vehicle operation safety and efficiency and causing damages not coveredby warranty.

Welding is permitted:

- When joining the sidemembers to extend or shorten the wheelbase or rear overhang.

- For the application of reinforcing L section flitch on a side member that is to be modified as detailed below (v. Figure 2.3).

Figure 2.3

91448

When arc welding, the instructions below must be followed in order to protect electric units and ECUs:

- before disconnecting power cables, check to ensure all electrical items are switched off;

- where an electric switch is installed (battery isolation switch) wait for cycle end;

- disconnect negative power pole;

- disconnect positive power pole without connecting it to ground and DO NOT short circuit it with negative pole;

- disconnect ECUs connectors, carefully and do not touch ECU connector pins;

- when welding within the electronic control devices, disconnect them from the vehicle;

- connect welding machine ground directly to the part to be welded;

- protect plastic pipes against heat sources and remove, if necessary;

- if welding near leaf springs or air springs protect against welding spatters;

- avoid electrode or gun contact with spring leaves;




Operations for welding preparation

As part of the procedure it will be necessary to remove the paint and deoxidise the parts of the chassis that are affected by thewelding operation as well as those parts whichmay have to be covered by possible reinforcements.When work has been completedthe modified part must be protected with adequate rustproofing (see point 2.2.2).

a) Cut the side members with a diagonal or vertical cut. (We recommend that the diagonal cut be used particularly for the sectionbetween the wheelbase) Cuts are not permitted in areas in which the profile of the side member as well as the chassis widthchange or in those where there is a high concentration of stresses (e.g. spring brackets). The cuts must not be made throughthe holes present in the side member (see Figure 2.4).

91446

Figure 2.4

YES

YES

b) On the inner side of the side member give the parts that are to be joined a V-shaped chamfer of 60° along the entire lengthto be welded (see Figure 2.5).

c) Arc weld in stretches using carefully dried basic electrodes. The recommended electrodes are:

For S 500 MC (FeE490: QStE 500TM)Diameter of the electrode is 2.5 mm, current intensity approx. 90A (max. 40A for each millimetre of diameter of the electrode).Using MIG-MAG welding use a welding rod with the same characteristics as the material to be welded (diameter 1 to 1.2 mm).Recommended welding rod: DIN 8559 - SG3 M2 5243

gas DIN 32526-M21 or DIN EN 439If FeE490 is used at very low temperatures, we recommend:PrEN 440 G7 AWS A 5.28 - ER 80S - Ni 1gas DIN EN439-M21Avoid current overloading. Welding must be free from marginal cuts and waste material.

d) Repeat the operation on the reverse side by welding as detailed in point c).

e) Allow the side members to cool slowly and uniformly. Cooling by air, water or other means is not permitted.

f) Remove excess material resulting from the welding operations by grinding.




91447

Figure 2.5

g) On the inner side reinforcing L-section flitches should be applied. These should be made of steel and have the same characteris-tics as the steel used for the chassis. The minimum dimensions are given in Figure 2.3.The reinforcements may only be fixed to the vertical web of the side member using welding beads, plug welds, bolts or rivets(Huck rivets may also be used).The cross-section and the length of the weld bead, the number and distribution of the plug welds, bolts or rivets must be ad-equate to transmit the bending and shearing moment of the section.

2.3.5 Closing of existing holes

If, when making new holes, the existing holes are found to be too close (see Figure 2.2) these may be closed up by welding. Toensure the success of this operation the outer edge of the hole should be chamfered and copper plate used for the inner part.

For holes with a diameter of over 20 mm, chamfered plugs may be used, welded on both sides.



Modifying the Wheelbase


2.4 Modifying the Wheelbase


!Any change to thewheelbase affecting the electrical circuits and/or entailing a relocationof the electri-cal/electronic components must be approved and performed according to the instructions providedin chapter 5.

As a rule, for each vehicle, modification to the wheelbase must be carried out on the standard wheelbase above or closer tothe new wheelbase required.The measurements given in the written authorisations will apply in all cases particularly for extensions made to the longest standardwheelbase.Frame cuttingmust be performed according to the indications given at point 2.3.4.Whenever permitted by the body size, wheelbasesshould be made equal to those planned in our production. This enables the original transmission shafts and previously defined cross-member positions to be used.When extending awheelbase beyond the production longest planned, the vehicle usedmust have the longest production wheelbaseto ensure the correct thickness side members are used. Particular care must be taken to comply with the limits set by national regula-tions particularly with regard to the limits for overall dimensions (where specified). Use only material shown at point 2.3.2.

2.4.2 Authorisation

The alteration of the wheelbase for the 4x2 versions is permitted without specific approval by IVECO in the following cases:- If the wheelbase is to be lengthened and the new value is still within the standard range of length with the same side membersection. These sizes are given in the specific technical documentation or in Table 2.8 and Table 2.9.

- If the wheelbase is to be shortened without falling below the standard minimum values established for each model.

Provided the chassis converter gives sufficient guarantees from the technological and control point of view (qualified personnel,adequate operating processes, etc.).For the 6x2 and 6x4 versions the wheelbase may only be modified following specific approval by IVECO.Conversion must be carried out performed in compliance with these instructions by making the necessary changes and adjustmentsand taking the appropriate precautions (e.g., determining whether ECU parameters need updating, rearranging the exhaust pipes,ensuring compliance with specific load limits on the rear axle, etc.), by taking into due account the requirements specified for theoriginal wheelbase lengths.

2.4.3 Effects on the steering

Generally, lengthening the wheelbase has a negative effect on the steering.Whenever national regulations require it, the limits on the overall dimensions must be observed as well as the limits concerningthe effort applied on the steering wheel and the relevant operation times (e.g. ECE - R 79/01 standard or current EC Directive).Tables 2.11 contain, the wheelbase extension limits for the various models, with series drive, at max load admissible on front axleand with tires admissible on vehicle.Should vehicles with longer wheelbase be needed, for special applications, it will be necessary to fit various devices aimed at improvingthe steering characteristics such as a reduction in the maximum permitted load on the front axle or the installation of wheels andtyres with shorter kingpin offset values (Table 2.17).The fitting of an additional pump and a dual circuit power steering unit, if not immediately available, will require authorisation andmust only be installed by an authorised workshop.




2.4.4 Effect on braking

Generally, shortening the wheelbase has a negative effect on braking characteristics.Table 2.11 gives the wheelbase alteration limits. Ask an authorised IVECO dealer for the conditions (brake cylinder, minimum taresettings see section, technically permitted masses, tyres, height of centre of gravity) under which these values are permissible.

Table 2.11 - Maximum permitted wheelbase lengthening depending on the load on the front axle and tyre dimensions(ECE - R79/01 regulation and EG/70/311)

ModelsMax. load on front axle(observe tyre carrying

capacity)

Max wheelbase valuebetween 1st steeringaxle and 1st driving

axle (mm)

Kingpin offset(mm)

Steering wheeldia. (mm)

AS/AD/AT 190(without CM)

8000 6050 120 470

AS/AD/AT 190/FP-CM 80008000

57006700

120120

470510

AS/AD/AT 260 Y/P, Y/FP(without CM)

8000 6050 120 470

AS/AD/AT 260 Z/P - HM 8000 6050 120 470

AS/AD/AT 260 Y/FP -CM 80008000

45005100

120120

470510

AS/AD/AT 260 Y/PS, Y/FS

(with CM)

750075008000

570060505700

120120120

470510470

AS/AD/AT 440TX/P (E5) 7500/7500 3140 120 470

AS/AD/AT 260XP 7500/7500 3140 120 470

For tyre type see Table 2.17.

2.4.5 Recommended procedure

To ensure the success of the conversion proceed as follows:- Arrange the vehicle so that the chassis is perfectly level, using the appropriate stands.- Disconnect the propeller shafts, the braking system pipes, the wiring harness and any equipment that might prevent the workbeing carried out correctly.

- Identify the reference points on the chassis (e.g. pilot holes, suspension supports).- Mark the reference points with a light line of punch marks on the top flange on both side members after ensuring that their joiningline is perfectly at right-angles to the longitudinal axis of the vehicle.

- When re-positioning the spring hanger brackets, identify the new position using the reference marks made previously.Check that the new measurements are identical between the left and right sides. Differences no greater than 2 mm shouldemerge from diagonal checking of the lengths less than 1,500 mm.Unless another tool is available, make new holes by using the supports and gussets of the cross members as a template.Fix the supports and cross members with rivets or bolts. If using bolts, fix the supports by reaming the holes and using class 10.9calibrated bolts with nuts equippedwith a device that prevents them fromworking loose.When space permits it use flanged-headscrews and nuts.

- If cutting the chassis, make a second line of reference points so that the area affected by the modification is included betweenthese and the previous points (in any event ensure a distance of not less than 1500 mm. measured when the work has beencompleted). Inside these two reference lines make points to mark out the area of the cut then proceed as indicated in point2.3.4.Before welding, ensure that the side members, including any added portion, are perfectly aligned and take measurements onboth sides and diagonally to check, as previously described. Fit the reinforcements as instructed at point 2.3.4.




Further indications

- Protect the surfaces from oxidation as described in point 2.2.2.

- Restore the electrical and braking systems as described in points 2.15 and 5.5.

- For changes to the drive line follow the instructions given in point 2.8.

2.4.6 Chassis Stress Level

When lengthening a wheelbase, in addition to local reinforcement on the side member joint, the bodybuilder must provide suffi-cient reinforcements to achieve the section moduli of the side member section no lower than that designed by IVECO for the samewheelbase or for next size up. Alternatively, when permitted by local regulations, larger subframe sections can be used.

The body builder shall verify that such stress is not greater than the one of the chassis with the original wheelbase, by assuming anevenly distributed load and the chassis being considered as a beam resting on the suspension supports. In any case, more restrictivelimits (if any) set by the national standards shall be complied with.

When extending out from the longest original wheelbase the reinforcements must depend on the length of the extension, the typeof body built and the use to which the vehicle is to be put.

2.4.7 Cross Members

The necessity of applying one or more additional cross members depends on the length of the extension, the location of thetransmission shaft support, the welding area, the introduction points of the forces produced by the body and the condition underwhich the vehicle is to be used.

Any supplementary crossmembersmust have the same features as those already existing (flexural strength, torsional strength, qualityof thematerial, connection to the side members, etc). In Figure 2.6 shows an example of the application. A crossmember is mandato-ry for any extension over 600 mm.

As a general rule the distance between the two cross members must not be greater than 1000 to 1200 mm.

The minimum distance between two cross members must not be less than 600 mm, particularly for heavy-duty and off-road use;this limit does not apply to the ”lightweight” transmission support cross member.

91449

Figure 2.6

2.4.8 Changes to transmissions

See chapter 2.8 for admissible changes.



Modifying the Rear Overhang


2.5 Modifying the Rear Overhang


In modifying the rear overhang it must be borne in mind that such modification entails changes in the distribution of the payloadon the axles relative to the loads established by IVECO (see point 1.13). The limitations established by national laws must also berespected as well as the maximum distance from the rear edge of the body and the ground clearance prescribed for the tow hookand the underrun bar. The distance from the extremity of the chassis to the rear edge of the body must not, as a general rule, exceed350 to 400 mm.

Should the bolted rear cross member be re-positioned, the same standard type of connections should be maintained (i.e. numberof screws, dimensions, class of resistance).

When re-positioning rear cross members fastened by rivets, these can be replaced by flanged nuts and bolts with same diameteror by class 8.8 hexagonal-headed screws with the next largest diameter. Use self-locking nuts (do not use bolts with a diameterlarger than M14).

When the installation of a tow hook is planned an adequate distance (approximately 350 mm) must be left from the rear crossmember to the next nearest cross member for mounting and removing the tow hook wherever necessary.

If the modifications are carried out competently and in compliance with the specifications contained in this manual, the towableweight originally established may be retained. In any case responsibility for the work rests with those who have carried it out.

Authorisation

Authorisation from IVECO is not required, if the frame is extended at the rear, or is shortened to the minimum value admissiblefor each model as standard, provided that this is done according to the instructions given in this manual.

!If it proves necessarymodify the length of the electrical circuits, see chapter 5 “Special instructions forelectronic subsystems”.

2.5.2 Reducing the Overhang

If the rear overhang of the chassis has to be reshortened, the last cross member must be moved forward.

If, when reducing the overhang, the rear cross member is found to be too close to an existing cross member, the latter must beremoved if it does not affect the suspension supports.

2.5.3 Increasing the Overhang

Various methods of increasing the length are given in Figures, 2.7 and 2.8.

The framemay be straight cut. The minimum dimensions of the reinforcements the are to be fitted to the modified section are givenin Figure 2.3.

Figure 2.7 shows a typical method of extension for increases of 300 to 350 mm. In this case the reinforcing L-bars, which also serveto connect the crossmember and the chassis frame,must be of the same thickness andwidth as the original gusset plate. The connec-tion of the crossmember and the plates, originally achievedwith rivets, may bemadewith class 8.8 bolts with thenext larger diameter.




In those cases where the joint between the cross member and the gusset plate is made by means of a weld, it is permissible tojoin the gusset plate to the reinforcement by welding (see Figure 2.7).

When the increase exceeds 350 mm, Figure 2.8 shows the procedure to be used.

91454

Figure 2.7

1. Added portion - 2. Reinforcing runner - 3. Reinforcing runner (alternative solution) - 4. Original rear cross member

91455

Figure 2.8

1. Added portion - 2. Reinforcing runner - 3. Original rear cross member - 4. Supplementary cross member (if necessary)

So will be necessary to examine on a case by case basis, the feasibility of installing a supplementary cross member to give the framesufficient torsional rigidity. Adding a supplementary cross member with the same properties as the standard production cross mem-ber is necessary whenever the distance between two cross members is greater than 1200 mm.



Installing a Towing Device


2.6 Installing a Towing Device


Without prior authorisation, the installation of a tow-hook is permissible only on those cross members which are intended forthat use and on those vehicles which IVECO has intended for towing a trailer.

The subsequent installation of a tow hook in vehicles for which the installation of a tow hook was not originally contemplated, mustbe authorised by IVECO.

In addition to the permissible towing weight, the authorisation will specify all other possible specifications that are to be adheredto such as the use of the vehicle, the transmission ratio, the type of braking system as well as possible specifications concerningreinforcements to be applied to the rear cross member or the necessity for employing specially intended cross members.

In trailers with one or more axles close together (centre axle trailers), considering the stress resulting in particular from the verticaldynamic load to which the rear cross member is subjected, the instructions given in point 2.6.4 must be taken into account.

!The tow hook must be appropriate for the permitted loads and of the type approved by national laws.

Since tow hooks are important to vehicle driving safety (in some countries they must be specificallycertified) they must not be modified in any way.

When mounting the tow hook to the cross member, the specifications of the hook manufacturer as well as the limitations imposedby current standards - such as minimum space required for the brake and electrical connections the maximum distance betweenthe swivel hook axis and the rear edge of the body - must be respected.

This may vary as a function of national standards. In the European Community a maximum of 420 mm can be reached. If highervalues are required, check the EC Directive for the conditions to be able to accomplish this.

Should the fixing holes in the flange of the coupling hook not match the holes in the rear towing crossmember of the vehicle thenin certain cases re-drilling may be authorised in specific cases after applying appropriate reinforcements.

It is the bodybuilder’s responsibility to ensure that no part of the body or structure creates a hazard or impairs the maneuverabilityof the trailer.

The trailer drawbar must be free to move unobstructed.




2.6.2 Traditional towing hooks

Choice of hook for traditional trailers

The reference dimension for choosing the type of hook is defined by value D calculated as defined below.

Figure 2.9

116773

Free area for towing hooks

When selecting the appropriate hook and for the use of reinforcements for the rear cross member (where necessary), the effectof the horizontal forces produced by theweight of the tractor and trailermust be taken into account in accordancewith the followingformulas:

T x RT + R

D = 9.81 x

D = Representative value of the hook class (kN).T = Maximum weight of tractor, in t.R = Maximum weight of trailer, in t.




2.6.3 Towhook for mid-axled trailers

When using trailers with central axles or heavy single-axled trailers with enormous support loads (e.g. while braking or due tovehicle vibration caused by road surface irregularities), the final crossmember is subject to additional twisting stress and the bendingmoment on the protruding part of the frame is higher.

The towed load allowed for this type of trailer is therefore lower than that of normal trailers with a steering drawbar (see table 2.12).

For vehicles with very protruding crossmember or mid-axled trailers with high towed loads, a frame installation section (see table2.12) that is sturdier than the one specified for this type of construction may have to be used.

On trailer with a fixed towbar, the installation frame must be fastened to the vehicle frame from the edge of the frame to the begin-ning of the first rear axle suspension via the end blocks (replace consoles with end blocks or add more end blocks, see figure 2.12).The towhook holes on the different towing terminal crossmembers available for most vehicles (for specific orders or as a conversionproduct) correspond to a given attachment size.

For different towing terminal crossmembers, the towing loads shown in table 2.12 may generally be type approved for mid-axledtrailers provided the vehicle type is not subject to legal restrictions (e.g. engine power) or other construction units (e.g. transmissionunit, braking system).

For this reason, the values shown in table 2.12 must be confirmed in any case in writing by the frame manufacturer (e.g. in the typeapproval certificates, in the manufacturer’s certification).

The value of the maximum (static + dynamic) vertical load transmitted by the trailer to the hook can be determinedmore accuratelythrough the following ISO formula:

Fv = a · x2/l2 · C · 0.6 + S

Fv = Max vertical load (static + dynamic) transmitted by the trailer to the tow hook (kN)

a = Vertical acceleration in the drawbar/towing hook coupling area; depending on the rear suspension of the tractor for semi-trailer, use the following values:

- a =1.8 m/sec2 for vehicles with pneumatic suspension (or equivalent)

- a =2.4 m/sec2 for vehicles with other suspension types

x = Total length in mms of the loading area of the trailer (m).

l = Length of the trailer wheelbase (distance between drawbar towing eye centre and axle centre or trailer axle centre line)in m.

C = Total weight of trailer, R, minus the static load applied S (all values expressed in tons).

S = Static support load (kN).

0,6 = Deceleration factor.




Figure 2.10

Chassis reinforcement for centre axle trailers

1. Combined reinforcement - 2. Shear resistant connections (cleat plates) - 3. Subframe longitudinal runner -4. Vertical load on tow hook

102183

Table 2.12

Dimensions of flange (mm)Max. vertical loads permitted on hook

(kg) Maximum towable weight (kg)Dimensions of flange (mm)(hook class)

Static S Total load *(static+dynamic) Fv

Maximum towable weight (kg)for centre-axle trailers R

120x55 (G135 or G3) 400 1130 4500( )

650 1690 6500

140x80 (G140 or G4) 900 2340 9000

G150 950 2470 9500

G5 1000 2960 12000

160x100 G6 1000 4040 18000

81 G5 1000 4400 20000

700G61 1000 5120 24000

* Indicative values determined according to ISO/TCC22/SCI5/WG4 Annex A through the following formula Fv = 3 × C × 0.6 + S (see following page)




2.6.4 Lowered Rear Cross Member

If the type of trailer used requires that the tow hook be positioned lower than originally intended, IVECOmay issue authorisationfor the original cross member to be lowered or for an additional cross member (of the original type) to be fitted in a lower position.Figures. 2.11 and 2.12 give some examples of how this is done.

The installation of the new cross member in its new position must be carried out in the same manner as before, using the sametype (diameter and class) of bolt.

Figure 2.11

1. Original rear cross member - 2. Gusset - 3. Upside-down gusset - 4. Connecting angle piece

91456

The thickness of the outer reinforcing angles must not be less than the thickness of the side members of the vehicle. They mustcover a length which is at least 2,5 times the height of the side member itself (maximum 600 mm) and be made of material withthe properties indicated in point 3.1.1. The angles are to be attached to the web of the side members using all the bolts joining thecross member to the frame, integrating them with the other bolts so that, as a result of their number and location, they will takeinto account the greater moment transmitted. As a general rule, when the cross member is lowered by an amount equivalent tothe height of the side member, the number of bolts is increased by about 40%.

When an additional cross member is installed (see Figure 2.12) a central joining plate with a thickness commensurate with thatof the cross members, must be employed.

A device to prevent the bolts from loosening must be adopted for the joints.




Figure 2.12Version for chassis with long overhangs

Version for chassis with shortoverhangs

1. Original rear cross member - 2. Connecting angle piece - 3. Connecting plate - 4. Gusset plate -5. Pressed steel channel sections (same size as chassis) - 6. Space for rear sprung support

91457

Assurance should be given that the movements between the tow bar and vehicle conform to current regulations. As a general rule,the original towable mass can be confirmed by IVECO. In any event the responsibility for the work carried out will rest with thebodybuilder.The vehicle must be presented for inspection if local government regulations require it.In Figure 2.12 shows an example of a lowered supplementary cross member.When this solution is applied to short rear overhang vehicles, the external connecting plates must conform to the arrangementdescribed in Figure 2.12. Should the brackets of the underrun bar be modified, following the lowering of the rear cross member,the new version will be equivalent to the original in terms of attachment, strength and stiffness and the positioning of the lightschecked for compliance with the standards (local standards where applicable).




Table 2.13 - Longitudinal runner profiles of the subframe for centre axle trailers

Towable weight (R) static load on towhook (S) to centre axle (kg)

Models Wheel Max.body

R≤ 9500S≤ 950

R≤ 12000S≤ 1000

R≤ 14000S≤ 1000

R≤ 16000S≤ 1000

R≤ 18000S≤ 1000

R≤ 20000S≤ 1000

R≤ 22000S≤ 1000

R≤ 24000S≤ 1000Models

(Chassis section)(mm)

Wheelbase(mm)

bodyoverhang(mm)

Section modulus for each longitudinal section of subframeWx (cm3) depending on thematerial yield limit (N/mm2)(mm)

S235 = ST 37 = FE 360 = 240 S355 = ST 52 = FE 510 = 360

240 360 240 360 240 360 240 360 240 360 240 360 240 360 240 360

3800 970 - - - - - - - - - - - - - - - -

3800 1195 - - - - - - - - - - - - - - - -

3800 1825 - - - - - - - - 46 - 46 - 46 - 46 -

4200 970 - - - - - - - - - - - - - - - -

4200 1195 - - - - - - - - - - - - - - - -

4200 2050 - - 46 - 46 - 46 - 46 46 46 46 46 46 46 46

4500 1780 - - - - 46 - 46 - 46 - 46 - 46 46 46 46

AD AT 1904800 2455 46 - 46 46 46 46 46 46 57 46 89 46 89 46 105 46

AD AT 190,

115 t rear5100 1555 - - - - - - - - 46 - 46 - 46 - 46 -

115 t rear

289/199x80x6 75100 1960 46 - 46 - 46 - - 46 46 46 46 46 46 46 46 46

289/199x80x6,75100 2185 46 - 46 46 46 46 46 46 46 46 57 46 74 46 89 46

5100 2365 46 46 46 46 46 46 57 46 57 46 89 46 89 46 105 46

5500 2185 46 - 46 46 46 46 46 46 57 46 57 46 74 46 89 46

5700 2185 46 46 46 46 46 46 46 46 57 46 74 46 89 46 89 46

6300 2005 46 - 46 46 46 46 46 46 46 46 57 46 57 46 74 46

6300 2365 46 46 46 46 57 46 74 46 89 46 105 46 105 57 119 57

6300 2770 57 46 89 46 105 46 105 57 119 74 150 89 173 105 173 105

6700 3400 46 46 46 46 74 46 74 46 89 46 105 46 105 74 150 74

3800 970 - - - - - - - - - - - - - - - -

3800 1195 - - - - - - - - - - - - - - - -

3800 1825 46 - 46 - 46 46 46 46 46 46 46 46 46 46 57 46

4200 970 - - - - - - - - - - - - - - - -

4200 1195 - - - - - - - - - - - - - - - -

4200 2050 46 46 46 46 46 46 57 46 57 46 74 46 89 46 105 46

4500 1780 46 - 46 46 46 46 46 46 46 46 46 46 57 46 57 46

AD AT 1904800 2455 74 46 89 46 105 57 105 57 135 74 150 89 173 89 173 105

AD AT 190

13 0 t rear5100 1555 46 - 46 - 46 - 46 - 46 - 46 46 46 46 46 46

13.0 t rear

289/199x80x6 75100 1960 46 46 46 46 57 46 57 46 74 46 89 46 89 46 105 46

289/199x80x6,75100 2185 57 46 74 46 89 46 89 46 105 46 105 57 119 57 135 74

5100 2365 74 46 89 46 105 46 105 57 119 74 150 89 173 89 173 105

5500 2185 57 46 89 46 89 46 105 46 105 57 105 57 119 74 150 89

5700 2185 57 46 89 46 89 46 105 46 105 57 119 57 135 74 150 89

6300 2005 46 46 57 46 74 46 89 46 89 46 105 46 105 57 105 57

6300 2365 89 46 105 57 119 57 135 74 150 89 173 89 173 105 173 105

6300 2770 150 89 173 89 173 105 173 105 245 119 245 150 245 173 245 173

6700 3400 105 46 105 74 150 74 150 74 173 89 208 105 208 105 245 105




Table 2.13 - (continued) Longitudinal runner profiles of the subframe for centre axle trailers



R≤ 9500S≤ 950

R≤ 12000S≤ 1000

R≤ 14000S≤ 1000

R≤ 16000S≤ 1000

R≤ 18000S≤ 1000

R≤ 20000S≤ 1000

R≤ 22000S≤ 1000

R≤ 24000S≤ 1000Models


Wheelbase(mm)

bodyoverhang(mm)


S235 = ST 37 = FE 360 = 240 S355 = ST 52 = FE 510 = 360

240 360 240 360 240 360 240 360 240 360 240 360 240 360 240 360

3800 1847 - - 46 - 46 - 46 - 46 - 46 46 46 46 46 46

4200 1217 - - - - - - - - - - - - - - 46 -

4200 2072 46 - 46 - 46 46 46 46 46 46 46 46 46 46 57 46

4500 1307 - - - - - - - - 46 - 46 - 46 - 46 -

4500 1802 46 - 46 - 46 - 46 46 46 46 46 46 46 46 46 46

4800 2477 46 46 46 46 46 46 57 46 74 46 89 46 105 46 105 57

5100 1577 46 - 46 - 46 - 46 - 46 46 46 46 46 46 46 46

AS 190S /P,/FP,/FP-CM 5100 1982 46 - 46 46 46 46 46 46 46 46 57 46 57 46 74 46

11.5 t rear 5100 2207 46 46 46 46 46 46 57 46 57 46 74 46 89 46 105 465 t ea

289/199x80x6,7 5100 2387 46 46 46 46 57 46 57 46 89 46 89 46 105 46 105 57,

5500 2207 46 46 46 46 46 46 57 46 74 46 89 46 89 46 105 46

5700 1982 46 46 46 46 46 46 46 46 57 46 57 46 74 46 89 46

5700 2207 46 46 46 46 57 46 57 46 74 46 89 46 105 46 105 57

6300 2027 46 46 46 46 46 46 57 46 57 46 74 46 89 46 89 46

6300 2387 46 46 57 46 74 46 89 46 105 46 105 57 119 57 135 74

6300 2792 74 46 89 46 105 57 119 57 135 74 173 89 173 105 173 105

6700 3422 46 46 46 46 74 46 74 46 74 46 89 46 105 57 105 74

3800 1847 46 46 46 46 46 46 46 46 57 46 74 46 74 46 89 46

4200 1217 - - 46 - 46 - 46 - 46 - 46 - 46 - 46 46

4200 2072 46 46 57 46 74 46 89 46 89 46 105 46 105 57 119 57

4500 1307 46 - 46 - 46 - 46 - 46 46 46 46 46 46 46 46

4500 1802 46 46 46 46 57 46 57 46 74 46 89 46 89 46 105 46

4800 2477 89 46 105 57 119 57 135 74 150 89 173 89 173 105 173 105

5100 1577 46 46 46 46 46 46 46 46 46 46 57 46 57 46 74 46

AS 190S /P,/FP,/FP-CM 5100 1982 57 46 74 46 89 46 89 46 105 46 105 57 105 57 119 74

13.0 t rear 5100 2207 89 46 89 46 105 46 105 57 119 74 135 74 173 89 173 893 0 t ea

289/199x80x6,7 5100 2387 89 46 105 57 119 57 135 74 150 89 173 89 173 105 173 105,

5500 2207 89 46 105 46 105 57 119 57 135 74 150 89 173 89 173 105

5700 1982 57 46 89 46 89 46 105 46 105 57 105 57 119 57 135 74

5700 2207 89 46 105 46 105 57 119 57 135 74 150 89 173 89 173 105

6300 2027 74 46 89 46 105 46 105 57 105 57 119 74 135 74 150 89

6300 2387 105 57 119 74 135 89 173 89 173 105 173 105 173 105 208 119

6300 2792 173 89 173 105 173 105 173 119 245 135 245 150 245 173 245 173

6700 3422 89 46 105 57 105 74 150 74 150 74 173 89 208 105 208 105







R≤ 9500S≤ 950

R≤ 12000S≤ 1000

R≤ 14000S≤ 1000

R≤ 16000S≤ 1000

R≤ 18000S≤ 1000

R≤ 20000S≤ 1000

R≤ 22000S≤ 1000

R≤ 24000S≤ 1000Models


Wheelbase(mm)

bodyoverhang(mm)


S235 = ST 37 = FE 360 = 240 S355 = ST 52 = FE 510 = 360

240 360 240 360 240 360 240 360 240 360 240 360 240 360 240 360

3805 1757 46 46 46 46 46 46 46 46 57 46 74 46 74 46 89 46

4200 2117 74 46 89 46 89 46 105 46 105 57 119 57 119 74 150 89

AS 260 S Y/PT4500 2072 74 46 89 46 105 46 105 46 105 57 119 57 135 74 150 89

AS 260 S .. Y/PT

19 0 t rear4800 1712 46 46 57 46 74 46 74 46 74 46 89 46 105 46 105 57

19.0 t rear

289/199x80x6 74800 2072 89 46 89 46 105 46 105 57 119 57 135 74 150 89 173 89

289/199x80x6,75100 1802 74 46 74 46 74 46 89 46 105 46 105 46 105 74 105 74

5700 2432 105 46 105 74 150 74 150 74 173 74 208 89 208 105 208 105

6050 2657 150 74 150 74 173 89 208 105 208 105 245 105 245 105 286 150

3805 1757 57 46 74 46 74 46 74 46 89 46 105 46 105 57 105 74

4200 2117 105 46 105 57 119 57 135 74 150 89 173 89 173 105 208 105

AS 260 S Y/PT4500 2072 105 46 105 57 119 74 150 74 150 89 173 89 208 105 208 105

AS 260 S .. Y/PT

20 0 t rear4800 1712 74 46 89 46 105 46 105 57 105 74 135 74 150 74 150 74

20.0 t rear

289/199x80x6 74800 2072 105 57 119 74 150 74 150 89 173 89 208 105 208 105 208 105

289/199x80x6,75100 1802 105 46 105 57 105 74 105 74 150 74 150 74 173 74 208 89

5700 2432 150 74 208 89 208 105 208 105 245 105 245 135 286 150 286 150

6050 2657 208 105 245 105 245 105 245 150 286 150 286 150 317 173 343 208

3805 1757 89 46 105 46 105 57 105 74 135 74 150 74 150 74 173 89

4200 2117 150 74 150 89 173 89 208 105 208 105 208 105 245 105 245 119

AS 260 S Y/PT4500 2072 150 74 173 89 208 89 208 105 208 105 245 105 245 119 245 150

AS 260 S Y/PT

21 0 t rear4800 1712 105 74 150 74 150 74 150 74 173 89 208 89 208 105 208 105

21.0 t rear

289/199x80x6 74800 2072 173 89 208 89 208 105 208 105 245 105 245 105 245 150 286 150

289/199x80x6,75100 1802 150 74 150 74 173 89 208 89 208 105 208 105 245 105 245 105

5700 2432 245 105 245 105 286 150 286 150 286 150 317 173 343 208 343 208

6050 2657 286 150 286 150 317 173 343 208 343 208 374 208 374 245 406 245

3120 722 46 - 46 - 46 - 46 - 46 - 46 - 46 - 46 46

3805 1757 105 46 105 57 119 57 119 74 150 89 173 89 173 105 173 105

4200 1127 46 46 57 46 57 46 57 46 74 46 89 46 89 46 89 46

4200 1622 105 46 105 57 119 57 119 74 150 89 173 89 173 89 173 105

AS/AD/AT 260 S4200 2117 150 89 173 89 173 105 173 105 208 119 245 135 245 150 245 173

AS/AD/AT 260 S

Y/P Y/FP4500 1217 57 46 74 46 74 46 89 46 89 46 105 46 105 57 105 57

Y/P.., Y/FP 4500 1622 105 57 105 57 119 74 135 89 173 89 173 89 173 105 173 105

19.0 t rearI lid f i /

4500 1802 119 57 135 89 173 89 173 89 173 105 173 105 173 105 208 119Invalid for versions /TN /PT CT and GV

4500 2072 173 89 173 105 173 105 173 105 208 119 245 135 245 150 245 173TN,/PT CT and GV

289/199x80x6,74800 1487 105 46 105 57 105 57 119 74 135 74 150 89 173 89 173 105

289/199x80x6,74800 1712 119 57 135 74 150 89 173 89 173 105 173 105 173 105 208 119

4800 2072 173 105 173 105 173 105 208 119 245 135 245 150 245 173 245 173

5100 1802 150 89 173 89 173 105 173 105 173 105 173 119 245 119 245 135

5700 2432 105 46 105 74 150 74 150 74 173 74 208 89 208 105 208 105

6050 2657 150 74 150 74 173 89 208 105 208 105 245 105 245 105 286 150







R≤ 9500S≤ 950

R≤ 12000S≤ 1000

R≤ 14000S≤ 1000

R≤ 16000S≤ 1000

R≤ 18000S≤ 1000

R≤ 20000S≤ 1000

R≤ 22000S≤ 1000

R≤ 24000S≤ 1000Models


Wheelbase(mm)

bodyoverhang(mm)


S235 = ST 37 = FE 360 = 240 S355 = ST 52 = FE 510 = 360

240 360 240 360 240 360 240 360 240 360 240 360 240 360 240 360

3120 722 46 - 46 - 46 - 46 46 46 46 46 46 46 46 46 46

3805 1757 135 74 173 89 173 89 173 105 173 105 173 105 208 119 245 135

4200 1127 74 46 89 46 89 46 89 46 105 46 105 46 105 57 105 57

4200 1622 135 74 150 89 173 89 173 105 173 105 173 105 173 105 208 119

4200 2117 173 105 208 119 245 135 245 150 245 173 245 173 245 173 245 173

AS/AD/AT 260 S4500 1217 89 46 89 46 105 46 105 57 105 57 119 57 135 74 135 89

AS/AD/AT 260 S

Y/P Y/FP4500 1622 150 89 173 89 173 105 173 105 173 105 173 105 208 119 245 135

Y/P.., Y/FP

20 t4500 1802 173 105 173 105 173 105 208 119 245 119 245 135 245 173 245 173

20 t rear

289/199 80 6 74500 2072 173 105 245 135 245 150 245 173 245 173 245 173 245 173 245 173

289/199x80x6,7 4800 1487 119 74 135 89 173 89 173 89 173 105 173 105 173 105 173 105

4800 1712 173 89 173 105 173 105 173 105 208 119 245 135 245 150 245 173

4800 2072 208 119 245 135 245 173 245 173 245 173 245 173 245 173 343 173

5100 1802 173 105 173 105 208 119 245 135 245 150 245 173 245 173 245 173

5700 2432 150 74 208 89 208 105 208 105 245 105 245 135 286 150 286 150

6050 2657 208 105 245 105 245 105 245 150 286 150 286 150 317 173 343 208

3120 722 46 46 46 46 46 46 46 46 46 46 46 46 46 46 46 46

3805 1757 173 105 173 105 173 119 245 119 245 135 245 150 245 173 245 173

4200 1127 89 46 105 46 105 57 105 57 119 57 119 74 135 74 150 89

4200 1622 173 105 173 105 173 105 208 119 245 119 245 135 245 150 245 173

AS/AD/AT 260 S4200 2117 245 173 245 173 245 173 245 173 245 173 343 208 343 245 374 245

AS/AD/AT 260 S

Y/P Y/FP4500 1217 105 57 105 57 119 74 135 74 150 89 173 89 173 89 173 105

Y/P.., Y/FP

I lid f i /4500 1622 173 105 173 105 173 119 208 119 245 135 245 150 245 173 245 173

Invalid for versions /TN /PT CT and GV

4500 1802 208 119 245 135 245 150 245 173 245 173 245 173 245 173 245 173TN,/PT CT and GV

21 t rear4500 2072 245 173 245 173 245 173 245 173 245 173 343 208 343 245 374 245

21 t rear

289/199x80x6,74800 1487 173 89 173 105 173 105 173 105 173 119 208 119 245 135 245 150

289/199x80x6,74800 1712 173 105 245 119 245 135 245 150 245 173 245 173 245 173 245 173

4800 2072 245 173 245 173 245 173 245 173 343 208 343 245 374 245 374 245

5100 1802 245 135 245 150 245 173 245 173 245 173 245 173 245 173 317 173

5700 2432 245 105 245 105 286 150 286 150 286 150 317 173 343 208 343 208

6050 2657 286 150 286 150 317 173 343 208 343 208 374 208 374 245 406 245

4200 2117 105 - 105 - 105 - 150 - 150 74 173 74 208 89 208 105

4500 2072 105 - 105 - 135 - 150 74 150 74 173 89 208 105 208 105

AS/AD/AT 260 S4800 2072 105 - 105 - 150 - 150 74 173 89 208 105 208 105 208 105

AS/AD/AT 260 S

Y/FP GV5100 1802 89 - 105 - 105 - 135 - 150 - 150 74 173 74 208 89

Y/FP-GV

only with CCM 119545700 2432 173 89 208 105 208 105 245 105 245 150 286 150 286 173 317 173

only with CCM 11954

19 t rear- - - - - - - - - - - - - - - - - -

19 t rear

289/199x80x7 7- - - - - - - - - - - - - - - - - -

289/199x80x7,7- - - - - - - - - - - - - - - - - -

- - - - - - - - - - - - - - - - - -

- - - - - - - - - - - - - - - - - -







R≤ 9500S≤ 950

R≤ 12000S≤ 1000

R≤ 14000S≤ 1000

R≤ 16000S≤ 1000

R≤ 18000S≤ 1000

R≤ 20000S≤ 1000

R≤ 22000S≤ 1000

R≤ 24000S≤ 1000Models


Wheelbase(mm)

bodyoverhang(mm)


S235 = ST 37 = FE 360 = 240 S355 = ST 52 = FE 510 = 360

240 360 240 360 240 360 240 360 240 360 240 360 240 360 240 360

4200 2117 74 - 74 - 89 - 105 - 105 - 105 - 105 - 105 -

4500 2072 74 - 89 - 105 - 105 - 105 - 105 - 105 - 150 -

AS/AD/AT 260 S 4800 2072 74 - 105 - 105 - 105 - 105 - 135 - 150 - 150 74

Y/FP-GV 5100 1802 74 - 74 - 89 - 105 - 105 - 105 - 105 - 150 -Y/FP GV

only with CCM 11954 5700 2432 150 - 150 74 150 74 173 74 173 89 208 89 208 105 208 105only with CCM 11954

1200 towbar - - - - - - - - - - - - - - - - - -

19 t rear - - - - - - - - - - - - - - - - - -

289/199x80x7,7 - - - - - - - - - - - - - - - - - -

- - - - - - - - - - - - - - - - - -

- - - - - - - - - - - - - - - - - -

3800 1765 46 46 46 46 57 46 74 46 74 46 74 46 89 46 105 46

4200 1630 46 46 46 46 57 46 74 46 74 46 74 46 74 46 89 46

4200 2125 74 46 89 46 105 46 105 57 105 74 150 74 150 74 150 74

4500 1630 46 46 46 46 57 46 74 46 74 46 74 46 89 46 105 46

AD/AT 260 S /TN4500 1810 57 46 74 46 74 46 74 46 89 46 105 46 105 57 105 74

AD/AT 260 S ../TN

19 0 t rear4500 2080 74 46 89 46 105 46 150 57 105 74 150 74 150 74 173 89

19.0 t rear

289x80x6 74800 1495 46 46 46 46 46 46 57 46 74 46 74 46 74 46 74 46

289x80x6,74800 1720 57 46 74 46 74 46 74 46 89 46 105 46 105 46 105 57

4800 2080 74 46 105 46 105 57 105 74 150 74 150 74 150 74 173 89

5100 1810 74 46 74 46 74 46 89 46 105 46 105 57 105 74 150 74

5700 3025 245 105 245 150 286 150 286 173 317 208 343 208 374 208 406 245

6050 2665 208 89 208 105 245 105 245 150 286 150 286 150 317 173 343 208

3800 1765 74 46 74 46 74 46 89 46 105 46 105 57 105 74 135 74

4200 1630 74 46 74 46 74 46 89 46 89 46 105 46 105 57 105 74

4200 2125 105 57 105 74 150 74 150 74 173 89 208 89 208 105 208 105

4500 1630 74 46 74 46 74 46 89 46 105 46 105 46 105 57 105 74

AD/AT 260 S ../TN4500 1810 74 46 105 46 105 46 105 57 105 74 150 74 150 74 150 74

AD/AT 260 S ../TN

50:50 o 60:404500 2080 105 57 135 74 150 74 150 74 173 89 208 105 208 105 245 105

50:50 o 60:40

21 0 t4800 1495 57 46 74 46 74 46 74 46 74 46 89 46 105 46 105 46

21.0 t rear

289 80 6 74800 1720 74 46 89 46 105 46 105 57 105 74 105 74 150 74 150 74

289x80x6,7 4800 2080 105 74 150 74 150 74 173 89 208 89 208 105 208 105 245 105

5100 1810 89 46 105 46 105 57 105 74 150 74 150 74 150 74 173 89

5700 3025 286 150 343 208 343 208 374 245 406 245 406 245 406 286 474 286

6050 2665 245 135 286 150 286 173 317 208 343 208 374 208 374 245 406 245

6050 2665 317 208 343 208 374 208 374 245 406 245 406 245 406 286 474 286







R≤ 9500S≤ 950

R≤ 12000S≤ 1000

R≤ 14000S≤ 1000

R≤ 16000S≤ 1000

R≤ 18000S≤ 1000

R≤ 20000S≤ 1000

R≤ 22000S≤ 1000

R≤ 24000S≤ 1000Models


Wheelbase(mm)

bodyoverhang(mm)


S235 = ST 37 = FE 360 = 240 S355 = ST 52 = FE 510 = 360

240 360 240 360 240 360 240 360 240 360 240 360 240 360 240 360

3800 1765 89 46 105 46 105 57 105 74 150 74 150 74 150 74 173 89

4200 1630 89 46 105 46 105 46 105 57 105 74 150 74 150 74 150 74

4200 2125 150 74 173 89 205 105 208 105 245 105 245 105 245 150 286 150

4500 1630 89 46 105 46 105 57 105 74 105 74 150 74 150 74 150 74

AD/AT 260 S /TN4500 1810 105 57 105 74 150 74 150 74 173 74 208 89 208 105 208 105

AD/AT 260 S ../TN

21 0 t rear4500 2080 150 74 208 89 208 105 208 105 245 105 245 105 245 150 286 150

21.0 t rear

289x80x6 74800 1495 74 46 74 46 89 46 105 46 105 46 105 57 105 74 135 74

289x80x6,74800 1720 105 57 105 74 105 74 150 74 150 74 150 74 173 89 208 105

4800 2080 173 89 208 105 208 105 245 105 245 105 245 135 286 150 286 150

5100 1810 105 74 150 74 150 74 173 74 173 89 208 105 208 105 208 105

5700 3025 374 245 406 245 406 286 474 286 474 286 SP 317 SP 343 SP 343

6050 2665 317 208 343 208 374 208 374 245 406 245 406 245 406 286 474 286

2840 2072 46 - 46 - 46 - 46 - 46 46 46 46 46 46 46 46

AS 260 S X/P3140 1802 46 - 46 - 46 - 46 - 46 46 46 46 46 46 46 46

AS 260 S .. X/P

19 0 t rear3440 2477 46 46 46 46 57 46 74 46 74 46 74 46 89 46 105 46

19.0 t rear

289x80x6 73740 2387 46 46 57 46 74 46 74 46 74 46 89 46 105 46 105 57

289x80x6,74340 2207 74 46 74 46 74 46 89 46 105 46 105 46 105 57 105 74

4690 2657 105 46 105 46 105 74 150 74 150 74 173 74 208 89 208 105

2840 2072 46 46 46 46 46 46 46 46 57 46 74 46 74 46 74 46

AS 260 S X/P3140 1802 46 46 46 46 46 46 46 46 57 46 74 46 74 46 74 46

AS 260 S .. X/P

20 0 t rear3440 2477 74 46 74 46 105 46 105 46 105 57 105 74 150 74 150 74

20.0 t rear

289x80x6 73740 2387 74 46 105 46 105 46 105 74 105 74 150 74 150 74 173 89

289x80x6,74340 2207 89 46 105 46 105 57 105 74 150 74 150 74 150 74 173 89

4690 2657 150 74 173 74 208 89 208 105 208 105 245 105 245 105 286 150

2840 2072 57 46 74 46 74 46 74 46 89 46 105 46 105 57 105 74

AS 260 S X/P3140 1802 57 46 74 46 74 46 74 46 89 46 105 46 105 46 105 57

AS 260 S .. X/P

21 0 t rear3440 2477 105 57 105 74 150 74 150 74 173 89 208 105 208 105 208 105

21.0 t rear

289x80x6 73740 2387 105 74 150 74 150 74 173 89 208 89 208 105 208 105 245 105

289x80x6,74340 2207 150 74 150 74 173 74 208 89 208 105 208 105 245 105 245 105

4690 2657 208 105 245 105 245 105 286 150 286 150 286 150 317 173 343 208

AS 260 S .. Z/P-HM 3800 1487 46 - 46 - 46 - 46 46 46 46 46 46 46 46 46 46

19.0 t rear 4200 1847 46 46 46 46 46 46 46 46 57 46 74 46 74 46 74 469 0 t ea

289x80x6,7 4500 1982 46 46 46 46 57 46 74 46 74 46 74 46 89 46 105 46

AS 260 S .. Z/P-HM 3800 1487 46 46 46 46 46 46 46 46 46 46 57 46 74 46 74 46

20.0 t rear 4200 1847 57 46 74 46 74 46 74 46 89 46 89 46 105 46 105 570 0 t ea

289x80x6,7 4500 1982 74 46 74 46 89 46 105 46 105 46 105 57 105 74 150 74

AS 260 S .. Z/P-HM 3800 1487 46 46 57 46 74 46 74 46 74 46 74 46 89 46 105 46

21.0 t rear 4200 1847 89 46 105 46 105 46 105 57 105 74 150 74 150 74 150 740 t ea

289x80x6,7 4500 1982 105 57 105 74 135 74 150 74 150 74 173 74 208 89 208 105

See Table 3.2 (section bar dimensions)NOTE




Table 2.14 - Combined section reinforcement runner profiles Table 3.4

A B C or D E F G

Material yield point (N/mm2) ≤ 320 ≤ 320 ≤ 240 ≤ 240 ≤ 360 ≤ 360

Max. runner profile heightreduction (mm):

40 60 100 120 100 120

Combined reinforcements lengthLV : 0 5 LU 0 5 LU 0 8LU 0 85LU 0 8 LU 0 85 LULV :LH :

0.5.LU0.6.LU

0.5.LU0.6.LU

0.8LU0.95LU

0.85LU1.0.LU

0.8.LU0.95.LU

0.85.LU1.0.LU

Example: Combined section as analternative to the channel sectionC250x80x8 (mm)

210X80X8 190X80X8 150x80x8+ straightsection15x80

130x80x8+ straightsection15x80

150x80x8+ anglesection


Actual height reduction (mm): 40 52 85 97 92 104

The continuity of combined reinforcement runners can be interrupted only in special cases and is subject to authorisation. Similarly, when it is difficult to applyan external reinforcing L section (items F and G Figure 3.4) - owing to the presence of suspension mountings or air spring connection brackets - and the recessingto be performed could excessively reduce the section’s resisting capacity, the adopted solution will require special authorisation.

2.6.4.1 Centre axle trailers: towing cross member in lowered and forward positions(short coupling)

Vehicles designed to tow centre axle trailers for which a final cross member located in a lowered or forward position (nextto the rear suspension rear mountings or air springs) is evisaged, do not require particular chassis reinforcing devices. For the sub-frame, the runner profile dimensions indicated for the different types of equipmen t (e.g. see Table 3.4 standard bodies) will be suffi-cient. The bodybuilder will accurately work out the size and position of the chassis connection structure (see point 2.6.3 and 2.6.4)and make use of a suitable cross member and an appropriate towing hook.

The tow hook position will be such to permit anymovement between vehicle and trailer drawbar according to the various conditionsof use, to comply with the required safety margins and the standards and legal regulations in force (where applicable). In these casesthe standard underrun bar cannot be used, and the bodybuilder will investigate the possible permitted changes from specificationsor the specific solutions to adopt (e.g. tilt type underrun bar).

2.6.4.2 Reinforcement of Standard Rear Cross Member

When it is necessary to reinforce the standard crossmember andwhen original cross members are not available, the bodybuilderwill provide suitable reinforcements for which he shall be responsible.

These reinforcements may consist of C-sections mounted on the inside of the cross member. Care must be taken to ensure thatthe connections between the cross member and the side members are also reinforced following the procedures recommendedbelow, whenever stronger enforcements are required:

1) The mounting of a channel section on the inside of the cross member and joining it to the vertical web of the side memberor to the following cross member of the chassis, if it is situated in close proximity, in compliance with the procedures illustratedin Figure 2.13.




Figure 2.13

1. Original cross member - 2. Reinforcing rail - 3. Connecting angle pieces or plates

91459

2) Mounting a box section of suitable dimensions underneath the cross member, anchored at the extremities to the vertical webof the side members and joined at the centre of the cross member as shown in Figure 2.14.In vehicles having a short rear overhang and a subframe, the box section can be fitted within the subframe sections, above thecross-member, and connected to it by means of a plate (as shown in Figure 2.12).

Should box-section assembly require modification to underrun bar plates the original requirements for fastening, resistance and stif-fness must be met (comply with local government regulations if any).




Figure 2.14

1. Original rear cross member - 2. Box section - 3. Connecting plate - 4. Ribbing plate

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2.6.4.3 Tow hooks for Centre Axle Trailers

The use of centre axle trailers involues the use of tow hooks suitable for this purpose.

The values of the trailer loads and of the permissible vertical loads are contained in the technical documentation of the manufacturerof the tow hook or on the production data plate (e.g. DIN 74051 and DIN 74052).

There are also tow hooks with special type approval, whose values are greater than the ones mentioned in the above standards.These hooks may in any case be subjected to restrictions depending on the trailers used (e.g. drawbar length). In addition this canimply that the rear cross member should be further reinforced and a subframe runner of larger size be fitted.

2.6.4.4 Remarks about the Payload

It should be ascertained that the static drawbar load does not cause the allowable load on the rear axle or axles to be exceededand that the required minimum load acting on the front axle is adhered to see point 1.13.3.

2.6.4.5 Increasing the Towable weight

For those vehicles which IVECO regards as suitable for towing a trailer, a request may be submitted to evaluate the possibilityof authorising a towable weight exceeding that which is normally permitted.

Such authorisation will include the conditions that must be complied with and, where necessary, specifications concerning modifica-tions and work to be carried out on the vehicle.

These include possible reinforcements to the standard cross member (see Figure 2.13), the instructions for installing a reinforced crossmember when available, and those on the brake system to be made.

The tow hook must be suitable for the new use. Its connecting flange must match that of the cross member.

To fasten the cross member to the chassis frame, preferably use flanged head nuts and bolts or hex head screws of minimum class8.8. Use self-locking nuts.



Installing a Supplementary Axle


2.7 Installing a Supplementary Axle

!The installation of an additional axle has heavy repercussions on the vehicle systems; in particular, ithas a critical impact on the braking system, the compressed air system, the wiring harness and theMUX interconnection systems.Accordingly, the addition of an extra axlemust be approved by IVECOandmust be performedaccord-ing to the instructions given in chapter 5 “Special instructions for electronic subsystems”.


On certain models IVECO may authorise, upon request, the installation of a supplementary axle and, consequently, an increasein the total weight of the vehicle.

The modification must respect the weight limitations and the conditions imposed by IVECO as well as all other conditions that maybe imposed by national laws and such that are necessary to ensure the safety and proper functioning of the vehicle.

Diagrams of the installation procedure may be submitted for inspection. These proposals must indicate the parts necessary to con-nect the axle to the chassis as well as the reinforcements to, and modifications of the chassis. It is also necessary to submit diagramsshowing the changes made to the systems.

The specifications given in points 2.5 and 2.6 are to be followed for all modifications of the chassis.

In view of the increased stresses due to the increase in permissible load, and in consideration of the different phases of the dynamicstresses in operation as a result of the different reactions on the chassis when the axle is added, it is necessary to provide appropriatereinforcements to the chassis.

These reinforcements must in all cases satisfy all provisions of local applicable laws. The chassis that has thus been modified mustnot be subject to flexural stresses greater than those of the original chassis in the corresponding sections.

2.7.2 Chassis Frame Reinforcement

Figure 2.15 illustrates possible ways of modifying the chassis. The reinforcements must be continuous and must span the lengthof the entire frame of the vehicle up to the driver’s cab. For their attachment to the side member - when using L-bars - class 8.8reinforcement bolts must be used and their diameter and distribution must be such to enable the section reinforcements to providethe required strength.




Figure 2.15

1. Bracket - 2. Plate - 3. Screws, rivets or Ø 20 to 30 mm holes to be filled with welding

91461

Where an auxiliary frame is required as reinforcement (see point 3.1), the body mounting brackets on the chassis (if any) shouldbe used for the attachment. An alternative method of attachment is shown in point 3.1.2 and those that follow it.

We recommend using shear resistant connection in the area of the rear overhang up to approximately the mid wheelbase (or toa point no closer than 2 m from the front axle) (see Figure 2.15).

The fitting of reinforcing plates directly onto the flanges of the side members, using holes filled with welded material is not permitted.This is to avoid affecting the strength of the original sections caused by poor welding.

This procedure is only permitted in special cases with specific IVECO authorization when there are proven difficulties in subsequentbody applications.

It is possible to do without reinforcements on the frame if the static stress values in the Table 2.10 are not exceeded.

Any limitations, imposed by national regulations must be complied with.

Because of the deterioration of the material’s properties during the welding process, if the installation is unavoidable it is then advis-able to assume a reduction of 15% in the strength of the material when checking the load-effects acting on the various sectionsof the chassis.

As a general rule the thickness of the reinforcing plate must not exceed that of the flange of the original chassis.

The mounting must be carried out by skilled personnel and the bodybuilder will be responsible for any damage to the frame resultingfrom poor workmanship.




2.7.3 Installing a Rear Supplementary Axle

The installation of a rear supplementary axle generally implies that the chassis overhang should be lengthened, the extensionmust be carried out in compliance with the specifications given in point 2.5.3 relating to the modifications of the chassis, leaving thereinforcements mentioned above unaffected.

When an additional axle is added to the overhang with a section depth smaller than the depth within the wheelbase area the adjust-ment of the section to give a higher value could be a solution towards reducing the stress arising from the conversion.

In Figure 2.16 shows an example of the installation of a rear axle with an extension of the rear overhang.

Figure 2.16

1. Added supplementary axle - 2. Extension to the overhang - 3. Reinforcements for the modification of the chassis -4. Connections - 5. Reinforcing runner

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Installing an Intermediate Supplementary Axle

The installation of an additional axle in a forward (intermediate) position relative to thedrive axlemay require a possible reductionin the rear overhang (see point 2.5.2) in order to obtain the proper distribution of the weights (see Figure 2.18).

123841

1. Added supplementary axle - 2. Reinforcing runner - 3. Connections - 4. Reduction in the rear overhang

Figure 2.17




2.7.4 Steering Axles

Steering axles can be installed both intermediately and at the rear. They can be of the self-steering or force-steering types andbe designed and installed in such a way that the required dependability and road safety are guaranteed. The self-steering axle mustbe fitted with a device controlled from the driver’s seat which will lock the axle in the straight position when reversing.

The installation of an axle whose force-steering is obtained by means of the original steering system of the vehicle requires specificauthorisation from IVECO in relation to the suitability of the original components for the conversion in question. In this case, it willbe necessary for diagrams of the supplementary system to be submitted for our inspection.

2.7.5 Components and Suspension

Manufacturing quality of all components used (axle, suspension, braking units, systems etc) must be ensured in order to guaranteedriving safety and good vehicle operation.

Particular care and attention must be paid to the designing and construction of the suspension in consideration of its importancefor the proper performance and handling of the vehicle on the road.

The designed suspension may be either of the mechanical leaf-spring type, pneumatic with air actuated springs or of a mixed type.Whatever type is used it must not negatively affect the handling characteristics of the vehicle and its components in terms of drivingquality, comfort, road holding, working angle of die transmission and its working space in the case of an intermediate supplementaryaxle.

Where the additional axle has its own independent suspension, the suspension characteristics must be proportional to those ofthe original rear suspension in relation to the static loads applied to the two axles.

2.7.6 Stabilisers

When pneumatic suspension is used for the added axle, depending on the solution adopted, it may be further necessary to fitan antiroll bar in particular when a body with a high centre of gravity is used.

Similar measures must be adopted to ensure stability in relation to mixed type suspension on an additional rear axle.

2.7.7 Connection to the Chassis Frame

The connections of the added axle to the chassis must be such as to be able to withstand all longitudinal and transverse stressforces without transmitting them to the drive axle.

At the points in which the forces are introduced (spring supports, air spring brackets etc.), appropriate cross members or suitableframe reinforcements must be provided.

Ensure that the added axle is at right angles and aligned properly in relation to the longitudinal axis of the vehicle and the live axle.Check using the appropriate equipment available in the market.




2.7.8 Braking system for additional axle

!The braking system, considering its importance relative to the active safety of the vehicle, must beextremely well developed and constructed.

Braking units, hoses and joints of the same type as on the original vehicle must be used.The auxiliary axle must be equipped with the same brake components as those provided for the front axle.Use flexible pipes to form the connection between the fixed parts (chassis) and moving parts (axles).The braking torque must be proportional to the static and dynamic loads in order to provide an even distribution of the brakingaction to all the axles of the vehicle.The total braking capacity of the modified vehicle must, as a general rule, be proportional to that of the original vehicle, allowingfor the different total mass that is now applicable. The performance of the braking system (service, emergency and parking) mustin all cases satisfy the current government regulations in terms of deceleration, behaviour when hot, response time, efficiency ofengine braking and so forth.If the Technical Control Authority demands that the technical documentation regarding the braking system be submitted (e.g. ad-hesion curves, compatibility range diagram) this must be provided by the company in charge of the conversion or the manufacturerof the auxiliary axle.Upon request, technical documentation with characteristics and attainable performances of the braking system of the original vehiclemay be made available.For the construction of the braking circuit for the additional axle it is advisable to employ equipment and circuits specially providedfor each single model by the Manufacturer of the equipment in use on the original vehicles.Solutions are allowed that include direct connection between the additional axle braking section and the engine axle braking section.Check that the air tank capacity is sufficient for the size of the new additional brake cylinders. If necessary, fit a supplementary airtank.Current legal requirements must be complied with for the emergency and parking brake. We recommend that a parking brake isfitted on the additional axle.

!For indications of a general nature concerning the braking system, see the instructions given at point2.15.For the electrical system, comply with the indications provided at point 5.5.

2.7.9 Raise Device

The additional axle may be equipped with a raise device and may also be used in specific cases where permitted by governmentregulations, to increase the adhesion of the drive axle to the ground under certain conditions (starting uphill, slippery or snow/icecovered roads) provided that:- This modification is made conditional to the issue by IVECOof a permit in which themaximumpermitted load on the overloadedaxle is specified.

- The device is used only for driving short distances for the uses stated above, and at the maximum speed stated on the specificauthorization.

Some national regulations permit the use of the lifting device even during normal vehicle travel, provided that the max. type-approvalload specified for the drive axle and admissible speed limits are not exceeded.In such cases the indications given in point 1.13.2 should be heeded concerning the centre of gravity of the body plus the payload.Approval of and Responsibility for the Operations Carried OutFollowing conversion, the vehicle must be submitted to local authority technical control for approval (e.g.

single inspection or type approval).The authorisation given by IVECO to install an auxiliary axle and the passing of the approval inspection do not free the bodybuilder/converter from responsibility for the conversion in question, or its effect on the vehicle.For the added assemblies, the required service or maintenance operations with relevant schedule, consistent with the operationsand relevant schedule planned for the original vehicle must be defined and entered in the specific documentation.





2.7.10 Modifying the suspension

!Changes to the suspension can be made only with IVECO’s prior approval, the suspension being a sys-tem of decisive importance to riding safety.

As a general rule no modification of the parabolic springs is permitted. On vehicles equipped with these springs, installation ofelastic rubber components may be authorised for special versions or uses in order to increase the stiffness of the suspension. Invery specific cases, and for specific uses, the possibility may be evaluated of adding an extra leaf to the parabolic spring. This operationshould be carried out by a specialised firm following approval by IVECO.

The use on the same axle of one parabolic spring and one trapezoidal spring is not allowed.



Modifying the Drive Line


2.8 Modifying the Drive Line

Following the modification of the wheelbase, work on the transmission as a general rule, is carried out on the basis of the trans-mission of a similar vehicle with approximately the same wheelbase. The maximum value of the inclinations of the propeller shaftsused for standard production vehicles is to be retained. This rule must also be applied when any modifications to the suspensionand rear drive axles are made.

In cases of particular difficulty, the assistance of the company may be sought. A diagram giving the length and inclination of the pro-posed new transmission must accompany the request.

The purpose of the specifications contained in this manual is to ensure the proper functioning of the transmission, to limit its noiseand to avoid the build-up of stress transmitted from the engine assembly. In no way does this diminish the responsibility of the body-builder for the work he has completed.

2.8.1 Permitted lengths

The maximum operating lengths obtainable for both the intermediate shaft sections and the sliding shafts ”LG” or ”LZ” (seeFigure 2.18) can be determined according to the external diameter of the tube existing on the vehicle and the maximum operatingrotational speed (see formula). These are specified in Table 2.15.

For the propeller shaft length specified in Table 2.15 when the tube diameter is not sufficient, a new shaft section with the samecharacteristics as the existing shafts must be used. As an alternative, in some cases the transmission shaft with a larger diameter tubecan be used. The tube diameter required can be determined in compliance with the required length and the maximum rotationalspeed, directly from Table 2.16.

INTERMEDIATE SHAFT

C C

LZ LG

Figure 2.18

SLIDING SHAFT

SINGLE-SECTION SHAFT

116721




As far as sliding shafts are concerned, length LG is measured between the universal joint centres, with the sliding stub in its intermedi-ate position.As regards single-stub shafts, check both branches LG and LZ.The maximum working revs can be obtained using the formula below:

nG =nmaxiG

nmax = maximum number of engine revolutions (rpm).iG = gear ratio in fastest gear.iV = transfer box ratio, equal to 1 if not present or for shafts upstream of the transfer box.

The maximum propeller shaft speed is determined on the basis of the following formula (the necessary data may be obtained fromthe vehicle specifications and from the data plates on the engine, gearbox or transfer case).

nG =nmaxiG

ng = Max. prop. shaft speed (rpm).nmax = Max. engine speed (r.p.m.).iG = Gearbox ratio at top speed.

The greater thickness of the tube depends on the class, i.e. on the torque that the original shaft has to transmit and on the designof the driveline (torque, ratios of kinematic chain, power axle load).

A reference value for the thickness of the tube of a general validity cannot be given. When, for example, a tube of a larger diameteris to be used, its thickness should theoretically be reduced until the torsional strength of the original tube is achieved. It shouldhowever be noted that, to determine the thickness of the tube, the following points are to be taken into account: the size of themale element of the fork, the possible necessity of adapters and the sizes of the tubes available.

Therefore the thickness of the tube should be agreed upon as each occasion arises with the workshops authorised by the manufac-turers of the transmission shaft depending on its dimensions (i.e. size of the universal joint).

The minimum operating length (from flange to flange) must not be less than 800 mm for the sliding sections and 700 mm for theintermediate sections.

Table 2.15 - Obtainable propeller shaft characteristics

Max achievable lengths LG or LZ (mm)

Joint size Outer diameter xthi k ( )

1800 1900 2000 2100 2200 2300 2400 2500Joint size thickness (mm) Maximum number of propellershaft revolutions (rpm)

2040 100 x 4.5 3400 3150 2900 2650 2450 2300 2100 1950

2040 120 x 3 4450 4100 3750 3400 3150 2900 2650 2450

2045 120 x 4 4450 4050 3700 3400 3100 2850 2650 2450

2055 120 x 6 4400 4000 3650 3350 3100 2850 2600 2400

2060 130 x 6 4650 4250 3900 3600 3300 3050 2800 2600

2065 142 x 6 5000 4600 4200 3900 3600 3300 3050 2850




!Themaximum possible lengths given above refer to the original shafts; plan for shorter lengths (-10%)for shafts obtained for by modification.

2.8.2 Determining Driveshaft Positions

In the case of drive lines which consist of several shafts, the individual shafts must all be approximately of the same length. Asa general rule, the difference in length between a non sliding and a splined shaft (see Figure 2.19) must not exceed 600 mm. Thedifference in length between the shafts must not be more than 400 mm. A margin of at least 25 mmmust be left so that the slidingjoint can travel when the splined shaft is closed. When fully extended the shaft sliding sleeve should cover the splined stub for alength that should be about twice the diameter of the splined stub itself.

When the required length of the drive line exceeds the permissible length, an additional driven shaft must be provided as illustratedin Figure 2.19.

1. Engine, clutch, gearbox axis - 2. Intermediate shaft (non sliding) - 3. Intermediate shaft support - 4. Propeller shaft with slidingend - 5. Inclination of rear axle case (static load) - 6. Inclination of rear axle case (max. compression) - 7. Inclination of rear axle

case (unladen) - 8. Intermediate shaft and axle case axis must have the same inclination

Figure 2.19

91451




The intermediate shaft and the inclination of the rear axle case must be aligned accurately.The difference in their inclination relative to the engine-clutch-gearbox axis must not vary more than 1°. This can be achieved byfitting wedges between the rear axle and the springs, or by adjusting the rear axle reaction bars. The inclination of the rear axle mustnot exceed 5.5°

When, with a loaded vehicle, the rear axle flange is at a level which is lower than that of the gearbox flange, care must be takento ensure that the inclination of the differential housing and of the driven shaft are greater than the inclination of the engine-gearboxaxis. On the other hand, if, with a loaded vehicle, the rear axle flange is at a level which is higher than that of the gearbox flange,the inclination of the differential housing and of the driven shaft must be less than the inclination of the engine-gearbox axis.

When lengthening thewheelbase is substantial, it may become necessary to fit a supplementary intermediate shaft as shown in Figure2.20. In this case the same inclination must be maintained between the engine-gearbox axis, the second intermediate shaft and theaxis of the differential housing.

Figure 2.20

1. Engine, clutch, gearbox axis - 2. 1st intermediate shaft - 3. Intermediate shaft support - 4. 2nd intermediate shaft -5. Propeller shaft with splined end - 6. Inclination of rear axle case (static load) - 7. Inclination of rear axle case (max.

compression) - 8. Inclination of rear axle case (unladen) - 9. Gearbox, 2nd intermediate shaft and rear axle case axis must havesame inclination.

91452

Elastic supports must be fitted with the aid of supporting plates, at least 5 mm thick (see Figure 2.21), connected to cross-membershaving the same characteristics as those specified by IVECO.

When reducing the wheelbase it is recommended that the intermediate shafts are removed if the length of the splined shaft is lessthan approximately 800 mm.

Figure 2.21

1. Intermediate shaft - 2. Support bracket - 3. Backing plate - 4. Support of intermediate shaft

91453

If the drive line consists of a single shaft the inclination of the axle housing must be the same as the inclination of the engine-gearboxaxis.




The same holds true also for vehicles with separate gearbox. In addition to this, as a general rule, the wheelbase of such vehiclescannot be reduced beyond the measurement of the shorter wheelbase contemplated for standard production (tippers for example).

The use of original drive line parts from IVECO is recommended for these modifications however. Should this not be possible, har-dened steel tubes with a yield point of not less than 420 N/mm2 (42 kg/mm2) may be used.

Modifications to the universal joints are not permitted.

Whenever the transmission or part thereof, is modified, each modified section must be subjected to careful dynamic balancing.

!Since transmission is important to vehicle driving safety, it should be borne in mind that anymodification to itmust bearmaximumoperational guarantees.Only very specialised and transmissionmanufacturer-certified companies should therefore be employed to carry out work of this kind.

IVECO’s approval is not required, if the frame is extended at the rear, or is shortened to the minimum value admissible for eachmodel as standard, provided that this is done according to the instructions given herein.

!If it proves necessary modify the length of the electrical circuits, see chapter 5 “Special instructionsfor electronic subsystems”.



Modifications of the Engine Air Intake and Exhaust Syatem

Modifications of the Engine Air Intake and Exhaust Syatem

2.9 Modifications of the Engine Air Intake and Exhaust System

2.9.1 Intake

The specifications of the engine air intake and exhaust systems must not be altered without prior authorisation from IVECO.Modifications carried out must not alter the vacuum levels (for the intake) or the original exhaust back pressure levels.

Table 2.16 - Engine Back Pressures

Engines Engine Code Maximum exhaust backpressure (kPa)

Maximum intake backpressure (kPa)

CURSOR 8E31 F2BE3681CE33 F2BE3681B 20 6.5E36 F2BE3681A

CURSOR 10E42 F3A3681BE45 F3A3681A 19 6.5E46 F3A3681Y

CURSOR 13E41 F3B3681DE44 F3B3681GE45 F3B3681CE48 F3B3681F 28 6.5E50 F3B3681BE52 F3B3681EE56 F3B3681A

The air intake must be positioned to avoid the intake of hot air from the engine and/or dusty air snow or rain. The apertures forthe intake of air which may have to be made in the side of integral bodies, must have a working surface of not less than two anda half times that of the master hose located upstream of the filter. These apertures (e.g openings in the grill) must be of such a dimen-sion that they do not become obstructed. It is prohibited to alter the air filer or replace the original filter with a lower air capacityunit. Any connections on the intake duct must guarantee resistance of the tube to penetration by water or dust and free from sharp/rough edges (or welding burrs inside metal tube). It is not permissible to modify or substitute the original air filter.

2.9.2 Engine exhaust

The routing of the exhaust pipe must be as even as possible. Bends must not have an angle of less than 90º and the radii shouldnot be less than 2.5 times the external diameter. Avoid kinks and use cross-sections which are no smaller than those correspondingto the original system. Any connections on the intake duct must guarantee resistance of the tube to penetration by water or dustand absence of sharp edges or welding burrs inside the tube. Sufficient clearance should be maintained (min. 150 mm) betweenthe exhaust pipe and the electrical system, plastic hoses, the spare wheel, the plastic fuel tank (min. 100 mm), etc. Lower values(e.g. 80 mm) may be permitted if suitable sheet metal shielding is used. Further reductions require the use of heat insulation andthe substitution of the plastic tubes with steel pipes. It is not permissible to modify or substitute the original air filter; the silencerbody cannot be altered.Modifications to the silencer body and engine equipment (injectors, engine control unit etc.) are not permiss-ible as this may alter the correct functioning of the engine and adversely affect the emissions of gases from the exhaust.

Chapter 6 concerning SCR contains additional information on exhaust system changes.NOTE



Modification of the Engine Cooling System

Modification of the Engine Cooling System

2.10 Modification of the Engine Cooling System

The proper functioning of the original system, especially in connection with the radiator, the free surface of the radiator and hoses(dimensions and layout) must not be tampered with. Whenever modifications must be made that entail work on the engine coolingsystem (e.g., modifications to the cab), the following points must be considered:

- The useful area for the passage of air for the cooling of the radiator must not be less than that which is available on vehicleswith the standard cab. Maximum venting of air from the engine compartment must be ensured and care must be taken - possiblyusing shields or baffles - to avoid stagnant air pockets or back flow of air. The performance of the fan must not be altered.

- If it is necessary to re-position the hoses this must be done without affecting the complete filling of the system (which must occurat a continuous flowwithout forming blockages at themouth) or the normal flow ofwater. Themaximum stabilising temperatureof the water must not be altered even under the most severe operating conditions.

- Hoses must be located so that air pockets are not formed (i.e avoiding air traps and providing appropriate bleeding points) thatcould hinder the circulation of water. Check that the water pump primes immediately on starting the engine and later operateswith the engine idling (accelerate a few times, if necessary) even when the circuit is not pressurized. Check that the deliverypressure of the water pump, when the engine is running under no load and at maximum RPM, is not lower than 1 bar.

- Always reinstall the radiator anti-clogging protection after making alterations to the engine cooling system.



Installation of a Supplementary Heating System

Installation of a Supplementary Heating System

2.11 Installation of a Supplementary Heating System

When the installation of a supplementary heating system is deemed necessary, it is advisable to use the types recommendedby IVECO.

For vehicles on which IVECO has not planned the use of supplementary heaters, the installation should be carried out in compliancewith the supplier’s instructions (i.e. heater arrangement, piping, electrical system etc.) and following the directions given below.

All national rules and regulations relevant to the matter should be adhered to (i.e. inspections, particular installation for dangerouscargo transportation etc.). The supplementary heating system must not make use of the equipment that is specific to the vehiclewhich is subject to approval if the use is liable to impair or alter the performance of the equipment.

Furthermore:

- ensure correct operation of the vehicle components and equipment (i.e. cooling system);

- check the electrical system to ensure that the battery capacity and alternator output is sufficient for the higher current require-ments (see point 5.5). Provide the new circuitry with a protection fuse;

- connect the intake of the newly added fuel system to the reservoir connected to the engine fuel return line. Direct feed fromthe vehicle fuel tank is permitted only if this is independent from the engine fuel system and the new circuit is perfectly leakproof;

- trace pipe and cable paths, the location of brackets and hoses bearing in mind that the overall dimensions and heat affect thevarious units on the chassis. Avoid runs and arrangements that could lead to hazards when the vehicle is running. Use shieldsor armouring if necessary;

- When installing a water heater, original vehicle heating and engine cooling circuits are involved (see point 2.10), it is advisableto follow the instructions listed below to ensure reliability of the heating system and safe operation of the original system:

- special care must be taken when defining the connections between the supplementary equipment and the main one; referto IVECO, if necessary;

- determine a rational arrangement for piping, avoid neckings and siphonings;- install proper venting valve (bleeding points) to ensure proper filling of the system;- supplementary plugs should be installed to ensure draining of the system, if necessary;- proper insulation should be used to prevent heat dissipation.

- When air heaters are used and when the installation is to be made directly in the cab, make sure that the engine exhaust systemdoes not touch the added installation (to prevent exhaust gas circulation inside the vehicle) and have the correct warm airdistribution by avoiding direct air flows;

- the complete installation should be designed to ensure good accessibility for quick and easy servicing.



Installing an Air-Conditioning System

Installing an Air---Conditioning System

2.12 Installing an Air-Conditioning System

When the installation of an air conditioning system is deemed necessary, it is advisable to use the types recommended by IVECO.

If this procedure is not applicable, the installation must be carried out in accordance with the supplier’s instructions and the followingpoints:

- the installation must not interfere with the correct operation of the vehicle components and of equipment which may be con-nected with the installation;

- check the electrical system to ensure that the battery capacity and alternator output is sufficient for the higher current require-ments (see point 5.5.3). Provide the new circuitry with a protection fuse;

- in liaison with IVECO, establish a method for installing the compressor; if it is fitted to the engine, use the original IVECO com-pressor;

- trace pipe and cable paths, the location of brackets and hoses bearing in mind that the overall dimensions and heat affect thevarious units on the chassis. Avoid runs and arrangements that could lead to hazards when the vehicle is running. Use shieldsor armouring if necessary;

- the complete installation should be designed to ensure good accessibility for quick and easy servicing. At vehicle delivery, thebodybuilder will supply all service and maintenance instructions which are deemed necessary.

Furthermore, according to the system operations:a) Equipment installed inside the cab

- The condenser should not impair the original engine cooling system operation (reduction in the radiating area of the engineradiator).

- The best arrangement is to use a condenser, suitably ventilated.

- The arrangement of the evaporator-blower unit in the cab (if not planned by IVECO) should be designed to make sure thatthe accessibility control and operating equipment is not impaired.

b) Equipment fitted on the cab roof

- When the equipment (condenser, evaporator, blower) is fitted on the cab roof, make sure that its weight is not higher than thatpermitted for roof installation. Furthermore, the bodybuilder must provide proper reinforcement to the roof frame if necessary,in relation to the weight of the unit and the extent of the modification introduced.

- For specific applications with compressors not supplied by IVECO (e.g. fridge box), contact the IVECO offices in charge.



Cab Modifications

Cab Modifications

2.13 Cab Modifications


Any work on the driver’s cab must first be authorised by IVECO before any work is started.

Modificationsmust not prevent operation of the control devices located in the area affected by themodifications (e.g. pedals, linkages,switches, pipes etc) or alter the strength of the loadbearing elements (uprights, reinforcement sections etc.). Due care must betaken when carrying out work that may affect the cooling system and air inlet pipes of the engine.

When defining the position of payload, account must be taken of the variation in cab weight, in order to ensure the correct distribu-tion of the permitted loads on the axles (see point 1.13).

For operations that require the removal of sound deadening panels or internal protective elements (panelling, padding) restrict theremoval to the absolute minimum, taking care to restore the protective elements to their original condition, ensuring the previousoperating capability.

Controls and equipment (power take-off engagement control, external operating cylinder control etc.) may be fitted in the cab pro-vided that:

- They are positioned, properly and are easily accessible to the driver.

- Safety, control and warning devices are fitted which meet the requirements of use and safety of the vehicle and its equipmentas well as the requirements of national legislation.

Ensure that the pipes and wires are correctly positioned particularly when the cab is tilted. Use the necessary fixings taking care toobserve the appropriate distances from the engine, heat sources and moving parts.

Provide the necessary protection from corrosion for all modifications to the structure (see point 2.2).

Ensure that seals are fitted correctly and apply sealant to those areas which require it.

Ensure that a perfect seal is provided against the infiltration of water, dust and fumes.

The bodybuilder must check that after modification, the cab satisfies legal requirements regarding both the inside and outside ofthe vehicle.

2.13.2 Roof Panel Modifications

Installation andmodification work to achieve specific refurbishmentsmust be carried out with great care to safeguard the strengthand integrety of the cab and ensure that its operation and protection are maintained.

When fitting assemblies or devices on the roof, make sure that their weight does not exceed that permitted for the cab. These limitscan be supplied on request, as a function of type of superstructure.



Changing the Size of the Tyres


2.14 Changing the Size of the Tyres

Replacing the tyres with others of different sizes or with a different loading capacity with respect to those considered at the timeof vehicle type-approval must be approved by IVECO and it is also necessary to check for the need to reprogram the EBL or EBSsystem.

Changing the size of the tyres may involve replacing the wheels with others of a correspondingly greater loading capacity. In thiscase check whether the spare wheel carrier needs to be changed.

Mounting tyres of different sizes or types of construction on the same axle is prohibited.

Changing the size of the tyres may affect the ground clearance of the front and rear underrun guards, therefore the compliancewith the national legal requirements must be verified. Its supporting brackets, where necessary, may be replacedwith other appropri-ate, type-approved brackets.

The use of larger tyres always necessitates verification of the safety margins for the mechanical parts, wheel arches etc., under alldynamic conditions of steering and bump travel. In certain cases the use of wider tyres may entail a check on the axles to assessthe space required for the suspension components and the length of wheel studs etc.

Where there is local national legislation specifying overall widths (e.c. Jersey etc.) these must be complied with.

The use of tyres with a different outside diameter affects the performance of the vehicle in terms of speed, maximum gradability,pulling force, braking power etc. The tachograph must be recalibrated by an authorised workshop. The load capacity and the relativereference speed must always be compatible with the performance of the vehicle. When the tyres with a load capacity or speedlimit are chosen for a given vehicle, the permissible loads of the vehicle or its performance, must be reduced accordingly. On theother hand, the use of tyres with a greater load capacity does not automatically increase the maximum permissible weight on theaxles.

The size and load capacity of the tyres are established on the basis of international and national norms (ETRTO, DIN, CUNA etc.)and are listed in the manuals of the respective tyre manufacturers.

Specific performance characteristics may be established by government regulations for special use in the case of fire-fighting vehicles,vehicles for winter duty, airport tankers, buses etc..Whenever so required by government regulations the vehicle must be presentedto the respective government agency for inspection of the parts that have been replaced and entry of the respective modificationsin the vehicle documents.




Table 2.17 - Tyre configuration

Tyre size Rim Steel wheeloffset (mm)

Aluminiumwheel offset (mm)

285/60R22,5 8.259.0

9889

10599

295/60R22,5 8.259.0

9889

10599

305/60R2,5 8.259.0

9687

10394

315/60R22,5 9.0 87 97

385/55R22,5 11.75 115 125

385/65R22,5 11.75 110 120

275/70R22,5 7.5 99

305/70R22,5 8.259.0

9384

10094

315/70R22,5 9.0 82 94

275/80R22,5 7.58.25

9591 95

395/080R22.5295/80R22.5

8.259.0

8980

9691

315/80R22,5 9.0 79 89

Tyre loading capacity is given in the individual manufacturers’ manuals.



Modifications to the Braking System


2.15 Modifications to the Braking System


!Thebraking systemwith its components represents anelement of crucial importance to vehicle safety.

It is prohibited tomake changes to units such as the brake force control system, distributor, brake cyl-inders, valves, etc, which are rated as safety components.

Any changes to the braking system (changes to the piping, fitting additional operating cylinders, etc.)require prior authorisation from IVECO.

For new equipment we recommend the same make as those fitted to the original vehicle.

When required by national regulations, the vehicle must be submitted for testing to the respective authority.

In the event of the regulating valves, air drier etc., being moved, reinstate the same type of installation as originally envisaged, verifyingcorrect operation. In addition, operations carried out on the air drier must not affect cooling of the air supplied by the compressor.

2.15.2 Brake Pipes

When the wheelbase or rear overhang of the chassis are modified, the brake pipes concernedmust be replaced by a single lengthof new pipe. Where this is not possible the connectors used must be of the same type as those used originally on the vehicle.Whenreplacing observe the minimum internal dimensions of the existing pipes.

The new pipes must have the same characteristics and be of the same material as those used originally on the vehicle. The installationmust be carried out so that the piping is protected and the correct function of the system ensured.

For the supply and fitting of material we recommend that you contact our Parts Centres or specialised workshops.

Plastic Pipes

When fitting new pipes or replacing others, plastic must not be used for the following:

- in areas where the temperature reaches more than 80°C (e.g. within 100 mm of the engine exhaust system).

- Between fixed and moving parts, in this case special hoses are to be used.

- On the hydraulic lines.

During modification the following must be observed:

- Material and dimensions Standard DIN 74324 (Iveco Standard 18-0400)(max. operating pressure 11 bars)

- Radii of curvature : min. 6 Ø outer dia(referred to the pipe centreline)




Preparation and installation (Iveco Standard 17-2403)

Cut the pipe at right angles (max. permissible variation 15°) using the correct tools to avoid flaws which could impair tightness.

Mark the portion of the length L (see Figure 2.22) to be inserted in the connector with indelible ink or adhesive tape to ensuretightness. Mark the pipe to avoid confusion while it is being installed for subsequent modifications.

The Voss connector configurations are as shown in drawing 504225097.

91463

End of stroke mark

Marking15°max

Figure 2.22

d (mm)

6

8

10

12

16

L(mm)

19.8

20.5

24

25

27.1

Table 2.18 - Configuration of the new connectors VOSS - SV214/W

Type pipe∅

coupling∅

VOSSreference

IVECOreference

GENERAL NOTESPossible couplings with other connectors

6 6 5214010000 504149122

Straight connector ∅ 6IVECO No. 504148941 with thread M10x1IVECO No. 504148950 with thread M12x1.5IVECO No. 504148962 with thread M12x1.5IVECO No. 504148965 with thread M22x1.5

Intermediate connector ∅ 6 - 6IVECO No. 504149318

SV 214/W

8 8 5214010200 504149132

Straight connector ∅ 8IVECO No. 504148948 with thread M10x1IVECO No. 504148956 with thread M12x1.5IVECO No. 504148963 with thread M16x1.5IVECO No. 504148966 with thread M22x1.5

Intermediate connector ∅ 8 - 8IVECO No. 504149327

6 5214010700 504149133 Straight connector ∅ 12IVECO No. 504148959 with thread M12x1

8 12 5214010900 504149136

IVECO No. 504148959 with thread M12x1IVECO No. 504148964 with thread M16x1.5IVECO No. 504149016 with thread M22x1.5

12 5214011100 504149139 Intermediate connector ∅ 12 - 6/8/12IVECO No. 504149332




Table 2.19 - Configuration of the new connectors VOSS - SV214/GV SV214/GE

Type SW key pipe∅

Receptacleconnectorthread

VOSSreference

IVECOreference

GENERAL NOTESPossible couplings with other

connectors

6 5214012000 504149318 90° connector ∅ 6IVECO No. 504149122 coupling ∅ 6

8 5214012100 504149327 90° connector ∅ 8IVECO No. 504149132 coupling ∅ 8

SV 214/GV12 5014012200 504149332

90° connector ∅ 6IVECO No. 504149133 coupling ∅ 12




L connector ∅ 12IVECO No. 504149170 coupling ∅ 12

T connector ∅ 12IVECO No. 504149174 coupling ∅ 12

22 (2x)8

m16 x 1.5 5214006400 504140020 90° connector ∅ 8IVECO No. 504149132 coupling ∅ 8

24 12

M18 x 1.5(with sealingtaper seat withpipe j 16)on one side

5214006200 504149022




SV 214/GE28 (2x)

12M22 x 1.5 5214006000 504149021 L connector ∅ 12

IVECO No. 504149170 coupling ∅ 12SV 214/GE

28 12

M22 x 1.5(inner threadM16 x 1.5)on one side

5214006100 504149026 T connector ∅ 12IVECO No. 504149174 coupling ∅ 12




Table 2.20 - Configuration of the new connectors VOSS - SV214/W VOSS - 214/L VOSS - 214/T

Type pipe∅

VOSSreference

IVECOreference

GENERAL NOTESPossible couplings with other connectors

SV 214/W

5214011600 504149148

Straight connector ∅ 12

SV 214/L

12 5214011200 504149170

Straight connector ∅ 12IVECO No. 504148959 with thread M12x1.5IVECO No. 504148964 with thread M16x1.5IVECO No. 504149016 with thread M22x1.5

Receptacle connector ∅ 12IVECO No. 504149022 with thread M18x1.5IVECO No. 504149021 with thread M22x1.5IVECO N 504149026 i h h d M22 1 5

SV 214/T

5214011300 504149174

IVECO No. 504149026 with thread M22x1.5

As a rule quick coupling connectors should be used. We recommend that the same makes present on the original vehicle be used.When necessary (e.g. near bends), connectors with metal inserts may be used. Before inserting the pipe into the connector the lattermust be screwed into its threaded seat on the component (e.g. pneumatic valve) adopting the tightening torques indicated below.

Table 2.21

Thread Tightening torque (Nm + 10%)

M 12 X 1.5 MM 24

M 14 X 1.5 MM 28

M 16 X 1.5 MM 35

M 22 X 1.5 MM 40

Insert the portion of the length L, previously marked, of the pipe into the connector applying force for 30 to 120 N depending on thedimension of the pipe.

The replacement of the components (valves etc.) is made possible since the coupling and connector may be internally rotated whilescrewing or unscrewing.




!Should piping be replaced:

1. If the connectors are of the Raufoss P5 type, use new connectors.

2. If the connectors areof theVoss 214 type, disassemble themusing the special pliers, then re-fit themon the new piping.

Installation of piping on vehicle

New pipes must be thoroughly cleaned inside before use (e.g. by blowing through with compressed air).

Pipes must be fixed in their correct position. The fixing clips must go right round the pipe. They may be of plastic, metal or rubber.

Observe adequate distances between the various fixing elements. As a rule a maximum distance of 500 mm for plastic pipes and600 mm for metal pipes is applicable.

For plastic pipes, in order to prevent distortion and tension on the connectors when fitting them, take the necessary precautionswhen working out the run and fitting the fixing brackets onto the chassis. Correct fitting of the fixing brackets will ensure that thepipes do not rub against the fixed parts of the chassis.

Observe the necessary safety distances from moving parts and heat sources.

When a pipe has to pass through the chassis frame (side or cross members) appropriate precautions must be taken to avoid damage.

A solution which can be used as a bulkhead connection for a straight or angled run is given in Figure 2.23:

Figure 2.23

1. Pipe - 2. Bulkhead connector - 3. Chassis

91464

!After completing any work either on the system or the equipment, the braking system must bechecked to ensure its efficiency.

For air systems, build up the pressure to its maximum value. Check for leaks in the areas affected bythe work carried out.

To ensure that the connections have been made correctly, the air reservoir for one axle may be discharged. This check can be perfor-med by reading the on-board gauge and, by working the brake pedal, by checking the pressure in the remaining brake section (orsections).

In hydraulic circuits, on completing the work, the normal air bleeding operation must be performed.




2.15.3 Electronic braking system control devices

!For any changes to the electrical circuits, read carefully chapter 5.

When modifying the wheelbase, the ABS modulators must be kept in their original position in relation to the rear axle. Theelectrical wires (harness) between the sensors on the rear axle and the control unit and between the control unit and modulatorsmust be modified accordingly by fitting the harness(s) from a longer wheelbase IVECO vehicle should there be insufficient lengthin the originals. Brake pipes upstream of the modulators must be similarly modified.

2.15.4 Taking air from the system

In vehicles with an air braking system it is possible to obtain small amounts of air from the air tank in the auxiliary circuit. Airshould only be taken in through a reflux valve that is able to prevent tank pressure dropping to below 8.5 bars in the service brakecircuit and auxiliary circuit.

Air must be taken in directly behind the brake system four circuit protection valve (output 24).

In the Stralis series, air may be taken in directly on the valve plate on connection 5 unless this is already in use (see Figure 2.24).

Figure 2.24

116722

If larger quantities of air are required a supplementary air reservoir must be fitted. In this case, it will be necessary to check that theair compressor fitted is capable of charging the brake system reservoirs within the prescribed times.

If necessary a larger capacity compressor must be fitted.



Repositioning Parts and Mounting Auxiliary Assemblies and Equipment


2.16 Electrical System: Modifications and Drawing-Off Power

Subject moved to chapter 5.5NOTE

2.17 Repositioning Parts and Mounting Auxiliary Assemblies and Equipment

Whenever, in the course of modifying the vehicle, it should become necessary to reposition assemblies such as the fuel tank,batteries or the spare wheel, such relocation is permitted provided that the functioning of these parts is not impaired and providedthat the same type of connections as originally in use are re-employed. Their transversal location on the vehicle’s chassis may not,when their weight requires it, be changed radically.

In the case of vehicles not equipped with a spare wheel carrier, and vehicles in which the spare wheel carrier must be relocated,the spare wheel must be secured to a suitable wheel carrier which allows the wheel to be readily removed.

To secure the spare wheel to the side of the vehicle with a support attached to the web of the side member, it is advisable to usea reinforcing plate on the inside or outside of the side member. The size of this plate must take into account both the weight ofthe wheel and the possible presence of other reinforcements on the side member (see Figure 2.25).

Figure 2.25

91470

In order to limit the torsional stresses on the vehicle chassis, we recommend that the plate be fitted where there is a cross member,particularly in the case of heavy units.

A similar procedure should be adopted when fitting additional units such as tanks, compressors etc. When positioning them, dueconsideration must be given to the distribution of the weights (see point 1.13.3).

In any event, an adequate distance of their height from the ground must be ensured with due consideration given to the use of thevehicle.

It is advisable to take measures to reinforce the frame depending on the weight of the construction parts. On request, Iveco is ableto provide further information on this topic.

Any holes that are necessary for the relocation must be made on the web of the side member in accordance with the specificationsgiven in point 2.3 Holes already present must be made use of to the greatest extent possible.

When tank refilling is hindered by the positions of the body structure, the tank mounting brackets may be installed one drilling unitlower (45 mm).




Supplementary fuel tank

If a supplementary fuel tank is to be added, the best solution is to use the same system arrangement already used for originalfuel tank, using, whenever possible, original elements. The use of a switching system allows the alternative feeding from the two tanks(see Figure 2.26).

Figure 2.26

91471

The use of the above system is advisable when the added tank is located on the side opposite the original one. When the tanksare in line on the same side it is possible to maintain fuel feed from the original tank then the added one should be connected directlyto the former through hoses. The arrangement must conform to national rules and regulations. The tank-to-tank connecting linemust be leakproof and not of a smaller internal dimension, have the same technical characteristics as those envisaged for the originalsystem and be properly secured.

Table 2.22 - Stralis AT-AD, Cursor 8 engines, available tanks

Fuel tanksModel Engine 200L

Plastic300L

Aluminium400L

Aluminium600L

Aluminium800L

Aluminium800L+400LAluminium

S27AT-AD190SAT AD190S/P

S30 standard opt 6170opt 6172 opt 6173 opt 6177

-AT-AD190S/PAT-AD190S/FP-D S31

opt 6172 opt 6173 opt 6177AT AD190S/FP D

S35 - standard opt 6172

AT-AD440ST/P S31standard opt 6172 opt 6173 opt 6177

-AT AD440ST/PAT-AD440ST/P - HR S35

- standard opt 6172 opt 6173 opt 6177opt 7855

AT AD260SY/PTS27

standard opt 6170AT-AD260SY/PTAT-AD260SY/TN

S31standard opt 6170

opt 6172 opt 6173 opt 6177-

AT-AD260SY/TNS35 - standard opt 7855

AD260SX/PS27

AD260SX/PAD260SX/FP

S30 - - - - - -AD260SX/FP

S31

AT AD260SY/PS27

AT-AD260SY/PAT-AD260SY/PS S30 standard opt 6170

opt 6172 opt 6173 opt 6177-AT AD260SY/PS

AT-AD260SY/FP-DAT AD260SY/FS D

S31opt 6172 opt 6173 opt 6177

AT-AD260SY/FS-DS35 - standard opt 7855




Table 2.23 - Stralis AT-AD, Cursor 10 engines, available tanks

Fuel tanksModel 300L

Aluminium400L

Aluminium600L

Aluminium300L+300LAluminium

800LAluminium

600L+300LAluminium

800L+400LAluminium

AT-AD190SAT-AD190S/PAT-AD190S/FP-D

standard opt 6172 - opt 6177 - opt 7855

AT-AD190S/FP-CT - - - standard - opt 7854 -

AT-AD440ST/PAT-AD440ST/P - HR

standard opt 6173 - - opt 7855

AT-AD440ST/P - LT - - - standard - opt 7854 -

AT-AD440ST/P - CT

AT-AD260SY/PTAT-AD260SY/TN

standard opt 6172 opt 6173 - opt 6177 - opt 7855

AT440S43TZ/P standard opt 6172 opt 6173 - - - -

AT-AD260SY/PAT-AD260SY/PSAT-AD260SY/FP-DAT-AD260SY/FS-DAT-AD260SY/FS-CM

standard opt 6172 opt 6173 - opt 6177 - opt 7855



Transporting hazardous goods ADR


2.18 Transporting hazardous goods ADR

Vehicles used to transport dangerous Goods - for instance inflammable materials or explosives - must be built in compliancewith the safety specifications established for this type of transport by national or international regulations.

Stralis vehicles may be fitted with option 2342 (ADR) in combination with option 8818 (Digital Tachograph for ADR).

The optional 2342 consists of:

- special electric disconnector positioned on frame.

- Disconnector control switch positioned in cab.

- Emergency switch.

- Protected electrical connections.

- Wiring protected using polyamide sheath.

- ADR type approval plate.

- Operating instructions.

If option 2342 is fitted, central door locking is not available.

On the assumption that the Bodybuilder is aware of, and in compliance with, the particular specifications relative to this subject wewould like to recall, nonetheless, that all vehicles crossing borders within Europe must be in compliance with the ”European Agree-ment on international transport of dangerous substances on roads” (ADR), now included in the specific EC Directive.

As a case in point, we list below some of the requirements in the above mentioned Agreement (ADR), which in any case must becarefully examined:

1) Electrical equipment.Electric wiring must be suitably insulated and protected in conduits from impact, stones, heat etc.Circuits must be protected against overloads by fuses or automatic disconnectors.A general circuit breaker (excluding the tachograph supplied directly by the batteries) with suitable safety devices, located closeto the batteries, with direct or remote control in the cab or outside.

2) Braking:Compliance with the specific EC Directives.Anti-lock braking system (ABS) and retarder compulsory in the cases required by the law.

3) Protection of the cab.Use of virtually flameproofmaterials, in conformity with ISO 3795,with combustion speeds no greater than 100 mm/min.Other-wise, have a protective wall between the driver’s cab and the transported container.

4) Exhaust system.Those parts of the exhaust system which reach temperatures of more than 200ºC and cannot be moved in front of the protec-tive wall, must be adequately insulated.If the exit of the exhaust cannot be turned outwards, in the case of tranporting explosives, it must be equipped with a sparkarresting device.(If any modifications of the exhaust pipes are necessary, they must be carried out in accordance with point 2.9).

5) Fuel tank.This needs to be positioned so it is protected against bumps. In the event of it over turning or of leakage, the liquid has to runoff straight onto the ground.




6) Independent heater.This must be safe as regards fire protection. It has to be positioned in front of the cab rear panel, at least 80 cm off the ground,with the heated parts protected.

7) Speed limiting device.Compulsory for vehicles with GVW greater than 12 m.t., in compliance with current EC Directives and set to 85 km/h.

8) Safety equipment.A minimum of two fire extinguishers, two portable lamps that are independent from the electrical system of the vehicle, andwhose operation cannot cause the combustion of the cargo being transported.

9) 3rd axle.The electric lifting device for the 3rd axle has to be positioned outside the side members of the chassis frame, in a watertightbox.

Check the availability of these outfits for our models with IVECO.



Retarder installation

Retarder installation

2.19 Retarder installation

!Retarder brakes other than those supplied as options cannot be fitted on Stralis.IVECO does not allow fitting any type of retarder brake system after-market.For this reason, no approval will be given for the application of retarder brakes.

Any unauthorised interventions or changes concerning brake functionality will void the vehicle warranty.



Modifications to the Rear Underrun

Modifications to the Rear Underrun

2.20 Modifications to the Rear Underrun

Our vehicles are fitted with a rear underrun bar in accordance with EC Directive.

The maximum permitted distance from the bar to the rearmost part of the body is 400mm. For further information see the officialinformation issued by IVECO.

Whenever chassis modifications affect the rear overhang, the underrun barmust be repositioned (in compliancewith current regula-tions) so as to be able to obtain the same connection with the chassis as on the original vehicle.

When modifying the vehicle or installing special equipment (e.g. tail lifts) it may be necessary to modify the structure of the underrunbar. Suchmodificationsmust not change the original resistance and stiffness specifications (comply with local government regulations,if any). The firm carrying out the modification must be prepared to present the relevant documentation on the required specifica-tions upon request.

Whenever a different underrun bar must be used, check relevant current regulations. Documentation or quality control certificatesmust be presented upon request from the competent authority.



Rear Mudguards and Wheel Boxes

Rear Mudguards and Wheel Boxes

2.21 Rear Mudguards and Wheel Boxes

When vehicles are supplied without mudguards, the bodybuilder must fit them using similar installations are used by IVECO onsimilar vehicles. The following points must be observed:

- Ensure the wheels can turn without any foul conditions even in the full bump condition with snow chains fitted, in compliancewith the limits shown in the documentation supplied by IVECO.

- On vehicles with lifting axles sufficient space must be allowed for the axle to fully lift without the tyres fouling any structure,following the instructions given the relevant documentation.On the 6x2/PS and FS (Steering Version 2)the axle also steers when the axle is raised, therefore sufficient space must be allowedfor this function as shown in Figure 2.27. The dimensions shown refer to 315/80R22.5 tyres, allow another 50mm if 385/65R22.5tyres are fitted.

- The maximum width of the vehicle over the tyres must comply with the legal limits.

Figure 2.27

116725

When fitting mudguards or making whell boxes the following points should be considered:

- The supporting structure should be sufficiently strong enough, avoiding any sudden variation in section.

- If the supports are fixed to the web of the sidemembers they must be bolted, the sidemembers must not be welded (see Figure2.28).

If the supports are fixed the body longitudinals they can be welded or bolted.

Figure 2.28

116726



Mudflaps

Mudflaps

2.22 Mudflaps

If legally required, unless already fitted ex-factory, the bodybuilder must ensure that the complete vehicle is fitted with mudflaps.When mounting them legally required distances must be complied with.



Side Guards

Side Guards

2.23 Side Guards

In some countries local or EC regulations require that the vehicle be fitted with side guards. The Bodybuilder who finishes offthe vehicle must ensure compliance with the required characteristics unless it is already equipped with them ex-factory.

On permanently fitted structures such as fixed platform bodies, vans etc, the side guards will be fitted directly to their basic structure(floor ribbings cross members) whereas on mobile structures (such as tippers, interchangeable equipment, removable containers),the side guards will be connected to the auxiliary frame by way of suitable brackets or installed directly on the chassis. In the lattercase, we suggest that the Bodybuilder makes use as far as possible, of the holes already existing on the side member vertical webin compliance with point 2.3.

According to the EC regulation, the external protection element can either consist of a single runner whose surface extends in thevertical direction or of several longitudinal sections with preset sizes and distances between them.

The side guards must be connected to their own supporting structures in order to allow quick removal or tilting shouldmaintenanceor repair work on assemblies or components located next to them be needed.

Operation of and access to the following parts must be ensured:

- Brake system equipment.

- Air inlet system

- Fuel supply.

- Batteries.

- Suspension.

- Spare wheel.

- Engine exhaust.

The guards must be made of the appropriate materials (e.g. FeE420).

Particular care must be taken when fitting to ensure the clearance from the ground and the distances to the various componentsrequired by the regulations.

In Figure 2.29 shows a type of side guard designed in compliance with the relevant EC Directive to be fitted to fixed bodies (availableon request). The illustration also shows a specimen of a support designed for the combined fastening on the side guard and therear wheel mudguard which can be fitted to mobile auxiliary subframes.

The Bodybuilder will take care of the preparation and the arrangement of the side guard depending on the type of auxiliary subframeconcerned, as it is not possible to provide instructions of a general character applying to all equipment versions.



Side Guards

A For IVECO sectionB Either the bottom part of the auxiliary frame is over 1,300 mm from the ground

or the width of the auxiliary subframe is less than the external space occupiedby the tyres.

C Test load 1 kN Permitted sag values under test load:≤ 30 mm on the rear, included in the last 250 mm of the device≤ 150 mm on the remaining parts of the device

D Supporting structure for the combinedfastening of the side guard and rear mudguard.

Section A-B Detail “X”

D

Figure 2.29

116727

C



Chocks

Chocks

2.24 Chocks

Usually these are fitted directly at the factory. Should this not be the case, or if it is necessary to change their original position,the Bodybuilder must work out a new arrangement in compliance with local regulations. The new position must ensure reliabilityand safety as well as easy access for operation by the user.



Chocks

BUILDING & MOUNTING THE STRUCTURES 3-1STRALIS AS/AT/AD Euro 4/5


Index

Index

SECTION 3

Building & Mounting the structures

Page

3.1 Subframes and Bodies 3-3

3.1.1 Material (steel subframe) 3-3

3.1.2 Material (Aluminum Subframe) 3-4

3.1.3 Longitudinal section dimensions 3-5

3.2 Elements making up the subframe 3-6

3.2.1 Longitudinal Runner Profiles 3-6

3.2.2 Cross Members 3-9

3.3 Connections between frame and subframe 3-11

3.3.1 Choosing the Type of Body Mounting 3-11

3.3.2 Body Mounting Characteristics 3-11

3.3.3 Connection with Brackets 3-12

3.3.4 Connection with Greater Elasticity 3-13

3.3.5 Connection with U-bolts (clamps) 3-14

3.3.6 Connection with cleate (shear resisting) plates to contain longitudinal and transverse forces 3-15

3.3.7 Mixed Connection 3-16

3.4 Fitting Box-bodies 3-17

3.4.1 Fixed bodies 3-17

3.4.2 Tipper Bodies 3-20

3.4.3 Heavy-duty Service 3-22

3.4.4 Light-duty Service 3-22

3.4.5 Containers 3-23

3.5 Tractors for Semitrailers 3-24

3.5.1 Position of the Fifth Wheel 3-24

3.5.2 The Fifth Wheel 3-24

3.5.3 Coupling of Tractor and Semitrailer 3-24

3.5.4 Fifth Wheel Mountings 3-26

3-2 BUILDING & MOUNTING THE STRUCTURES STRALIS AS/AT/AD Euro 4/5


Index

Page

3.5.4.1 Preparation and installations of a Structure Working together with Chassis 3-32

3.5.4.2 Converting a Truck into a Semitrailer Tractor 3-34

3.5.4.3 Variable height fifth wheel (only for Low tractor) 3-34

3.6 Transport of Indivisible Materials (bascules) 3-35

3.7 Installation of Tanks and Containers for Bulk Materials 3-36

3.8 Installing a crane 3-39

3.8.1 Crane Behind the Driver’s Cab 3-40

3.8.2 Crane on Rear Overhang 3-43

3.8.3 Removable Cranes 3-45

3.9 Installation of Tail Lifts 3-46



Subframes and Bodies

3333.3


The following detailed instructions complement the general information given in Chapter 1.NOTE

3.1 Subframes and Bodies

The purpose of an subframe (subframe) is to ensure a uniform distribution of the load on the vehicle’s chassis and to increasethe strength and rigidity of the main frame in relation to the particular use of the vehicle.

The following points are to be borne in mind when constructing a subframe:

3.1.1 Material (steel subframe)

Usually, provided the subframe is not to undergo great stress, the material used for its construction may be of a lower gradethan that used for the vehicle chassis. It must have goodwelding characteristics and limits of no less than valoes (1) shown in Table 3.1.

Should the stress limits require it (e.g. if cranes or tail lifts are to be fitted), or if very high sections are to be avoided, material withbetter mechanical characteristics may be used. In this case it should be considered that a lower inertia moment of the reinforcingbeam implies high bending stresses on the chassis frame.

The properties of some materials that can be considered for the applications indicated are as follows.

Table 3.1 - Material to be used for body manufacturing continued

Steel name Breaking load(N/mm2)

Yield point(N/mm2) Elongation A5

IVECO FE360D

EUROPE S235J2G3360 (1) 235 (1) 25% (1)

GERMANY ST37-3N360 (1) 235 (1) 25% (1)

UK 40D

IVECO FEE420

EUROPE S420MC530 420 21%

GERMANY QSTE420TM530 420 21%

UK 50F45

IVECO FE510D

EUROPE S355J2G3520 360 22%

GERMANY ST52-3N520 360 22%

UK 50D




3.1.2 Material (Aluminum Subframe)

In the case of materials, having different characteristics compared to steel, such as aluminium, both the dimensions and the struc-ture of the subframe will have, as a rule, to be adapted accordingly.

When the subframe’s main function is mainly to distribute the load more evenly while leaving the major loadbearing to the frame,aluminium longitudinal runners can be used having the same dimensions as stated for the steel. Some typical examples are: fixedbodies, box bodies, tanks with continuous and close spaced bearers or bearers mounted directly over the suspension hanger brack-ets. Exceptions are those cases where the high stresses on the vehicle’s frame demand steel runners of a high dimension or shear-re-sistant connections.

When the subframemust contribute in terms of strength and stiffness (bodies having high concentrated loads, such as tippers, cranes,central axle trailers, etc.) aluminium is not recommended and has therefore to be authorised for each application.

It should be remembered that, when stating the minimum dimensions for the reinforcement runners, besides the admitted limit ofstress for the aluminium, the different elastic modulus compared to steel (approx. 7,000 kg/mm2 as against 21,000 kg/mm2 for steel)will also have to be considered. This will result in larger dimensions for the runners.

Similarly, when the connection between frame and counterframe guarantees the transmission of shearing forces (connection viaplates), a new neutral axis must be defined for the section based on the different elastic modulus of both materials when checkingthe stresses at both ends of the single section.

In the final analysis, if the subframe has to contribute to the frames Strength / stiffness, higher sectional dimensions for the runnersmust be used if aluminum in to be used instead of steel.




3.1.3 Longitudinal section dimensions

The table below gives the values for the section modulusWx for C-section longitudinals recommended by IVECO. The indicatedWx value refers to the true section and allows for the section radii (this can be calculated with some approximation by multiplyingthe value obtained when considering the section made up of simple rectangles by 0,95). Longitudinals of different sections can beused instead of those shown provided the section modulus Wx and the moment of inertia Jx of the new C-section are not lowerthan those shown in the table.

Table 3.2 - Section bar dimensions

Strength modulusWx (cm3)

Recommended C-section profile(mm)

16 ≤W ≤ 19 80 X 50 X 4 80 X 60 X 4 80 X 50 X 5

20 ≤W ≤ 23 80 X 60 X 5

24 ≤W ≤ 26 80 X 60 X 6

27 ≤W ≤ 30 80 X 60 X 7 100 X 50 X 5

31 ≤W≤ 33 80 X 60 X 8 100 X 60 X 5

34 ≤W ≤ 36 100 X 60 X 6

37 ≤W ≤ 41 100 X 60 X 7

42 ≤W ≤ 45 80 X 80 X 8 100 X 60 X 8

46 ≤W ≤ 52 120 X 60 X 6 120 X 60 X 7

53 ≤W ≤ 58 120 X 60 X 8

59 ≤W ≤ 65 140 X 60 X 7 120 X 70 X 7

66 ≤W ≤ 72 140 X 60 X 8 120 X 80 X 8

73 ≤W≤ 79 160 X 60 X 7

80 ≤W ≤ 88 180 X 60 X 8

89 ≤W ≤ 93 106 X 70 X 7 180 X 60 X 7 140 X 80 X 8

94 ≤W ≤ 104 180 X 60 X 8

105 ≤W ≤ 122 200 X 80 X 6 200 X 60 X 8 180 X 70 X 7

123 ≤W ≤ 126 220 X 60 X 7

127 ≤W≤ 141 220 X 60 X 8

142 ≤W ≤ 160 200 X 80 X 8 240 X 60 X 8

161 ≤W ≤ 178 220 X 80 X 8 240 X 70 X 8

179 ≤W ≤ 201 250 X 80 X 7 260 X 70 X 8

202 ≤W ≤ 220 250 X 80 X 8 260 X 80 X 8

221 ≤W ≤ 224 220 X 80 X 8 280 X 70 X 8

225 ≤W ≤ 245 250 X 100 X 8 280 X 80 X 8

246 ≤W ≤ 286 280 X 100 X 8

290 ≤W ≤ 316 300 X 80 X 8

316 ≤W ≤ 380 340 X 100 X 8

440 380 X 100 X 8

480 400 X 100 X 8



Elements making up the subframe


3.2 Elements making up the subframe

3.2.1 Longitudinal Runner Profiles

The longitudinals of the added structure must be continuous, extending as far as possible forward to the front of the vehicleto include, if possible, the area of the rear support of the front spring, and rest on the chassis of the vehicle but not on the brackets.

In order to achieve a gradual reduction in the resistant section, the front ends of the longitudinal runner must be tapered upwardsat an angle of no more than 30°, or tapered in some other equivalent way (see Figure 3.1), ensuring that the front end in contactwith the chassis is suitably connected, min radius 5 mm.

91136

Figure 3.1

If the cab’s rear suspension components do not allow the entire runner to pass through, the latter may be shaped as shownin Figure 3.2. If the front part of the frame is subject to strong bending moments for certain types of construction (e.g. in the caseof a crane with its working field at the front), the installation profile must be upgraded to take into account these forces

91137

Figure 3.2

The construction of auxiliary frames either wider or narrower than the chassis structure is permitted only in particular cases(e.g. removable containers sliding on rollers operated by mechanical or hydraulic systems). In these cases a necessary precautionwill be that of ensuring a correct transmission of the forces between the auxiliary frame and the side member vertical web. Thiscan be obtained by inserting an intermediate runner profile shaped according to the vehicle’s side member or by applying a stiffenedconnecting L-section.




The vehicle chassis is shaped and therefore the subframe runner profile must follow the shape of the main side members. Shouldthe front part of the subframe be narrower than the chassis, either a number of suitably shaped U-sections or of angle L-sectionswith the appropriate gussetts can be installed on the outside of the subframe (see Figure 3.3).

A

91138

Figure 3.3

A. L section - B. Alternative solution - C. Channel section

C

B

The type of section of the runner must be determined with due consideration to the function of the subframe and to the typeof structure that is above it. It is advisable to use open U-sections if the subframe has to adapt itself elastically to the vehicle’s chassis,and to use box-type sections when added rigidity is needed.

Proper care must be taken to ensure a gradual change from the box- type section to the open type section. Some examples onhow this can be achieved are shown in Figure 3.5.

Cleat plates must not be used at the profile section of the sidemembers.NOTE




“A”

“B”

15mm platband (width equalto runner profile flange)

Chassis/subframe connectingangle section

Version “F”

Angle section thicknessequal to subframerunner profile)

Version “G”

“C”

“D”

“E”

Version

Special combinedsection runner profiles

Standard box-typerunner profiles

Gradual change from box-type to open-type section

Version “A”

Figure 3.4

There must be continuity between the longitudinal runners of the subframe and the vehicle. Where this is not possible, continuitymay be restored by fitting cleat plate brackets.If a rubber antifriction strip is inserted, specifications and thickness must be equal to those originally used by the Manufacturer (hard-ness 80 Shore, max. thickness 3mm). The application of antifriction material may prevent abrasive actions which can cause corrosionwhen using material with a different composition (e.g. aluminium and steel).

The minimum recommended dimensions are shown for the sidemembers with various bodies. These values are generally valid forvehicles with standard wheelbase and rear overhang (see Tables from 3.4 to 3.21). In all cases similar sections, whose moment ofinertia and resistance is not lower, can be used. It should be borne in mind that the moment of inertia, apart from being an importantfactor for the calculation of the share of bending moment to be applied, also represents the most adequate response to the degreeof torsional stress required for the specific type of connecting section in use. Therefore, the moment of resistance is a determiningfactor as regards the stress exerted on the material.




3.2.2 Cross Members

An adequate number of cross members, which should be positioned if possible adjacent to the body mounting brackets, arerequired to brace the two runners of the subframe.

The cross members may be of the open type (e.g. C-type) or, if greater rigidity is desired, of the closed box-type.

Suitable gusset plates must be used to connect the crossmembers to the longitudinals to ensure sufficient strength at the connection(see Figure 3.5). In cases, where greater rigidity is required for the connection, this can be achieved as illustrated in Figure 3.6.

Figure 3.5 Figure 3.6

Stiffening the Subframe

In the case of certain bodies, such as tippers, cement mixers, crane on rear overhang or bodies with a high centre of gravity,the subframe must be additionally stiffened at the rear end.

Depending on the degree of torsional stress, this must be done in one of the following manners:

- Joining the rear section of the longitudinal member by a box-frame construction.

- Box-frame construction, closed-section cross members (see Figure 3.7).

- Box-frame construction, whit a cruciform (see Figure 3.8).

- By applying in addition to the box-frame construction a longitudinal torsion-resistant bar (see Figure 3.9).

As a general rule, the box-frame construction of the longitudinal runners should not be used in the front end.

Figure 3.7




Figure 3.8

1. Subframe - 2. Cruciform

Figure 3.9

1. Subframe - 2. Box-section

Self-supporting Bodies as Subframes

A subframe (longitudinal runners and cross members) need not be fitted if self-supporting bodies are to be installed (e.g. rigid boxbody, tankers), or if the base of the structure to be fitted already serves the purpose of a subframe.



Connections between frame and counterframe


3.3 Connections between frame and subframe

3.3.1 Choosing the Type of Body Mounting

The selection of the type of connection to be used - if not provided initially by IVECO - is very important in terms of the subframeproviding strength and stiffness for the appropriate body type.The subframe connection may be flexible (brackets or clamps) or it may be rigid, resistant to shear stress (longitudinal or transverseplates); the choice must be made based on the type of body that is to be mounted (see points 3.4 to 3.8) analysing the stress forceswhich the additional equipment transmits to the chassis both under static and dynamic conditions. The number, size and type offixing device properly subdivided over the length of the subframe, must be such as to ensure a good connection between the vehiclechassis and the subframe.The screws and clamps must be of a strength class no lower than 8.8, the nuts must be equipped with devices that prevents themfrom working loose. The first fixing must be located, if possible, at a distance of approx. 250 to 350 mm from the front end of thesubframe.Any body fixing brackets already fitted on the vehicle frame must be used first.Compliancewith the position for the first mountingmentioned abovemust be ensured in cases where the body applies concentratedloads behind the cab and requires additional stability (e.g. cranes, front end tipping gears etc.) in order to prevent overstressing thechassis frame. If necessary, additional fixings must be fitted.If the body to be fitted has different characteristics to those permitted on the original chassis (e.g tipper on a haulage chassis), thebodybuilder must provide the appropriate mountings (e.g. the replacement of brackets by cleat plates in the rear area of the chassis).

When fixing the body to the frame, no welding is allowed on the frame of the vehicle, nor can holesbe drilled in the flanges of the sidemembers.

NOTE

When fixing the body to the frame, no welding is allowed on the frame of the vehicle, nor can holes be drilled in the flanges ofthe sidemembers.In order to improve the longitudinal or transverse securing of the connection, it is permissible to have holes in the top flanges ofthe side members, but only at the rear end of the members, over a length of not more than 150 mm, providing the fixing of anycross members that may be present is not weakened (see Figure 3.14). The mountings shown in Figure 3.15 may be used, usingthe screws which connect the rear cross member or underrun brackets to the chassis.

In all other cases, holes must not be drilled in the flanges of the sidemembers.NOTE

In all other cases, holes must not be drilled in the flanges of the sidemembers.

3.3.2 Body Mounting Characteristics

Flexible mountings (see Figure 3.10, 3.11, 3.12 and 3.13) permit limited movement between the frame and the subframe, andpermit the use of two parallel working strong sections. Each bears a part of the bending moment in proportion to its moment ofinertia.

For the rigid type of joint (see Figure 3.15) between subframe and chassis, a single strong section is obtained, provided the numberand position of the mountings are adequate to support the resulting shear stresses.When using sheer resisting plates to secure the subframe to the sidemembers, a single strong section is formed which has a higherstrength capacity when compared with the MTG made using brakets or clamps. This has the following advantages:- Lower height of the subframe profile under the same bending moment acting on the section.- Higher bending moment under the same subframe profile dimensions.- Further increase in the strength capacity, when the subframe is made up of high mechanical characteristic materials.




3.3.3 Connection with Brackets

A few examples of this type of connection (flexibility mounting), are shown in Figure 3.10.

A

Figure 3.10

A. Leave a clearance of 1 to 2 mm before tightening

1. Subframe - 2. Frame - 3. Shims

A

In order to ensure a flexible joint there must be a gap of 1 to 2 mmbetween the brackets on the frame and those on the subframebefore the securing bolts are tightened. Larger gaps are to be reduced by using suitable shims. Using bolts of proportional lengthimproves the flexibility of the connection.The brackets must be secured to the web of the vehicle’s side member only by means of bolts or rivets.

In order to guide and better contain the loads transversally, a slight protrusion of the brackets above the chassis is recommended.When the brackets are fitted flush with the upper flange of the side member, the lateral movement of the body structure must besecured by other means (e.g. using guide plates fixed only to the chassis - see Figure 3.13). When the front connection is of thecoli springstype (Figure 3.11), longitudinal securing must be ensured even in conditions of maximum twisting of the chassis (e.g. off-road).

When the chassis already has factory fitted brackets for the installation of a box-type body, these brackets must be used for theinstallation of the structure. The brackets fitted to the subframe or to the body must have characteristics of strength no lower thanthose of the original brackets fitted to the vehicle.




3.3.4 Connection with Greater Elasticity

Given that there is not a clear definition of range of torsion of the vehicle rigid structure, due to its tough mission, the structureflexibility is always requested, except for special uses (e.g. installation of cranes). A coil spring should be used on each side of theconnection points between frame and sub-frame.The detail of the body mounting and installation is as follows:

Figure 3.11

- Spring stiffness = 424 N/mm.- With the longitudinal hard on the top flange there must be a grap of 5 mm between the faces of the two brackets before theupper bracket is fixed to the longitudinal.

- The body securing bolt should be 14 mm diameter grade 8.8 and secured with lock nuts.- Flat washers 4 mm thick by 32 mm outside diameter (minimum in both cases) should be fitted between the spring and the headof the bolt and between the lock nut and frame bracket.

When using rubber inserts, use materials which gives a good working life (elasticity). The relevant instructions for the regularinspections of the body mounting for deterioration and the bolt torque must be given to the operation.

Figure 3.12

1. Element rubber.

The whole connection capacity can, if necessary, be re-established by fitting shear resisting plates from the rear spring front hangerbrackets ti the end of the frame instead of the normal factory body brackets.On installations where the vehicleis supported by means of hydraulic stabilisers (e.g. cranes, lifting platforms), the movement of theelastic connection should be limited to 30 ÷ 40mm to ensure sufficient coordinatedmovement of the subframe and avoid excessivebending moments on the original chassis.




3.3.5 Connection with U-bolts (clamps)

The most important mounting of this type is illustrated in Figure 3.13.

In this type of construction the bodybuilder must place metal spacers, between the flanges of the two side members and in thesubframe at the point where the U-bolts are located, in order to prevent the flanges bending when the U-bolts are tightened.

In order to guide and contain transverse movement of the structure attached to the vehicle’s chassis, this type of connection mustalso have guide plates that are attached only to the chassis as shown in Figure 3.13.

In order to keep the added structure from sliding and to increase the rigidity, it is necessary to provide positive attachment towardsthe rear with cleat plates to contain both longitudinally and transversal movement.

Alternatively it is also possible to use bolt-type connections at the rear end of the chassis as illustrated in Figure 3.14.

Due to the nature of this type of connection, its all-round use on the vehicle is not advisable.

Figure 3.13

1. Frame - 2. Subframe - 3. U-bolts - 4. Locking with a lock nut -5. Spacers - 6. Guide plates (where necessary)




Figure 3.14

1. Subframe - 2. Frame - 3. U-bolts - 4. Longitudinal transversal securing

3.3.6 Connection with cleate (shear resisting) plates to contain longitudinal and transverseforces

This type of fixing shown in Figure 3.15 is achieved by means of a plate that is bolted or welded to the subframe and is securedto the chassis by bolts or rivets. This ensures regeneration following longitudinal and transverse thrust and provides maximum rigidityto the whole.

When this type of joint is used, the following must be observed:

- The plate must only be attached to the vertical web of the main sidemembers.Before fixing ensure that the subframe is mounted correctly on the top flange with no gaps between the two mating surfaces.

- Use of cleat plates must be confined to the central and rear sections of the frame.

- The number of plates, thickness and number of securing bolts must be adequate for the transmission of the sections shear andbending moments. As a rule the thickness of the plate will be equal to that of the vehicles sidemember. These values can becorrectly determined by calculation according to the necessary elements.Good results can however be achieved taking the following into account:

The shear resistant plates and the omega brackets which are standard on some models are generally sufficient for normal bodiessuch as fixed loading platforms, tilting bodies, concretemixers, provided the conditions of paragraphs 3.3 and 3.4 aremet and comply,in terms of dimensions and positioning, with the normal bodies.

The shear resistant plates already fitted to the vehicles can on the other hand meet the requirements of all installations which causesmall bending moments on the vehicle frame (e.g. tail lifts, reduced capacity cranes).




When a body cause high bendingmoments on the frame and the relevant strength has to be increased bymeans of shear resistantplates between the frame and subframe, or the subframe height has to be limited as far as possible (e.g. towing of central axle trailers,crane on rear overhang, tail lifts), observe the following instructions:

Table 3.3

Frame/subframeti h i ht ti

Max. distance between thet li f th h i

Min. characteristics of the platessection height ratio centreline of the shearing

resistant plates 1) Thickness(mm)

Fixing hardwaredimensions (at least 3screws each plate) 2)

≤1.0 500 8 M 14

Table applies to all modelsNOTE

1) The number of bolts per plate enables a proportional increase in the distance between the plates (a double number of bolts enables greater distance betweenthe plates). In the bearing areas of the frame (e.g. supports of the rear spring, of the tandem axle spring and of the rear air springs) closer spaced plates willhave to be considered.

2) In case of limited thickness of both of the plates and the subframe, the connection should be carried out by means of spacers, so that longer bolts can be used.

Figure 3.15

3.3.7 Mixed Connection

On the basis of instructions given for the construction of the subframe (point 3.1) and considerations included in the general section,the mounting between the vehicle frame and subframe can be of the mixed type, i.e. it may be obtained through a rational use of elastic(springs), flexible connections (brackets, clamps) and rigid connections (plates for longitudinal and transversal anchorage).

As a guide it is advisable to have coli springsconnections on the front section of the subframe (at least two on each side) while plateconnections are recommended for the rear section of the vehicle when a stiffer structure is required for the whole assembly.



Fitting Box-bodies

Fitting Box---bodies

3.4 Fitting Box-bodies

3.4.1 Fixed bodies

See table in Chapter 1 to find out the volumetric weights required to determine the load distribution.

On standard cab vehicles, intended exclusively for road use, box- bodies are usually fitted on a support structure comprising longitudi-nal runners and cross members. The minimum dimensions of the longitudinal runners are specified in Table 3.4.

Table 3.4 - (for models of class AS 190 up to AS 260, the data given below apply to loads on front axle up to 8000 kg).

Wheelbase (mm)(referring to the driving axle on

Minimum reinforcing runner

Models (referring to the driving axle, onvehicles with 3 axles with third

rear axle)Section modulus Wx

(cm3)

AS/AT/AD 190; AS 1902)4) up to 63002) 893)

AS/AT/AD 260

p

up to 60502) (46)1)

1) Possible alternatively, using shear resistance connections for the entire length of the chassis and connection with brackets in the front area.

2) For vehicles with wheelbase up to 5700 mm and rear overhang up to 2300 mm, 120x60x6 mm section can be used (Wmin. 46 cm3); this profile is sufficientfor all 2 and 3 axle models up to 7500 kg on front axle.

3) For models with pneumatic suspension (190P; FP) with wheelbase up to 6300 mm and rear overhang over 2300 mm. When the maximum permitted rearload is used, the longitudinal runnermust use materials with a yield of over 320Nm/mm2 and be connected to the chassis by shear resistant plates (cleat plates).The plates should start approximately 1000 mm before the centre line of the drive axle and continue to the end of the chassis.

4) For models 6x2 P; FP; PS; PT; FT; with a rear overhang over 1800 mm (from the centre line of the last axle). When the maximum permitted rear axle loadis used, the longitudinal runner must be connected to the chassis by shear resistant plates. The plates should start approximately 1000 mm before the centreline of the drive axle and continue to the end of the chassis.

5) For section dimensions see Table 3.2

The attachment is carried out using the brackets arranged on the vertical web of the side members. If such brackets have notbeen provided by Iveco, they must be installed according to the specifications given in point 3.3. In order to provide an adequatelengthwise securing when brackets or clamps are used, it is good common practice to arrange a rigid joint (one on each side) onthe rear overhang, using cleat plates on the web or bolts on the upper flange of the side member (see Figure. 3.14 and 3.15).

The front of the body must be able to withstand the force applied to it by the transported load during sharp braking.



Fitting Box-bodies

Under no other circumstances may new holes be made in the flanges of the main side members.

In those instances in which the box-body uses supports that are raised above the subframe (such as crossmembers) it will be necess-ary to stiffen these supports in an appropriate manner in order to contain the longitudinalwise thrusts, as shown in Figure 3.16

Figure 3.16

1. Subframe - 2. Brackets - 3. Securing anchorages

For special builds when a reinforcing runner of limited height is needed, the subframe structure may be integrated with the bodyanchoring brackets matching the height of the whole longitudinal reinforcement runner (see Figure 3.17). In this case, rear wheelboxes may be fitted at the base of the fixture.



Fitting Box-bodies

Figure 3.17

In the case of self-supporting bodies whose bearing structure operates as a subframe, the above explained installation of thereinforcing runners need not be affected.

The application of box bodies and structures with high torsional (1), stiffness in general requires the use of elastic connections to-wards the front of the structure (2) to avoid excessive reduction of main chassis distortion in particularly demanding applications(3).

1) Es. vehicle preparation furgonato

2) Figures 3.11 and 3.12

3) In the anterior part they are had to apply plates that limit the side move of the superstructure in comparison to the chassis.



Fitting Box-bodies

3.4.2 Tipper Bodies

The use of tipping bodies, whether front end or three way, subjects the chassis to notable stress. For this reason it is most import-ant to select the right vehicle from among those intended for this use. Therefore we list here the specifications that must be adheredto for this type of construction subdivided according to light or heavy duty; in the Table 3.5 give the minimum runner dimensionsfor the subframe with which these vehicles must be equipped.

Furthermore any government regulations concerning these vehicles must also be adhered to.

Where Iveco offer a rear stabilizer bar as an option it is recommended this should be fitted.

The following points must be kept in mind:

- The subframe must be (see Figure 3.8 and 3.9) suitable for the vehicle type and for the specific operating conditions. It musthave adequately dimensioned longitudinals and cross members and be stiffened at the rear by box-type construction and cruci-form.Fixing the subframe to the chassis, flexible connections (brackets or clamps) must be placed at the front end, whereas the rearsection requires rigid-type joints (cleat plates, see Figure 3.16) to allow the added structure to contribute more to the rigidityof the whole. The ”omega” brackets can be used on vehicles which are already fitted with them.

- The rear tipping hinge must be fitted on the subframe as near as possible to the rear support of the rear suspension. In ordernot to impair the stability of the vehicle during tipping operations and not to increase excessively the stress on the chassis, itis recommended that the distances between the tipping hinge and the rear spring rear hanger or tandem centreline is observed(see Figure 3.21). If for technical reasons this cannot be achieved, small increases may be permitted provided a higher strengthsubframe is used, in order to increase the rigidity of the rear end. Where long bodies are needed to transport large volumes,it is advisable (in those cases where it is permissible) to lengthen the wheelbase of the vehicle.

- Great care must be given to the positioning of the lifting ram both in terms of providing supports of adequate strength and inorder to correctly position the mountings, it is advisable to place the ram to the front of the centre of gravity of the body andpayload so as to reduce the extent of the localized load into the chassis.

- For both under floor and front end tipping gear installations it is recommended that an appropriate stabilizer is fitted to act asa guide during the tipping operation.

- The lifting rammust be mounted on the subframe. The useful volume in the body must conform.With the maximum permissibleload on the axles. To the density of the material that is to be transported (a density mass of approx. 1600 kg/m3 is to be usedfor excavated material).When freight having a low density is transported, the useful volume may be increased within the limits established for the maxi-mum height of the centre of gravity of the payload plus the fixtures.

- The bodybuilders must ensure the functioning and safety of all parts of the vehicle (for instance, the positioning of lights, towhook etc.) is safeguarded and in full compliance with the current safety regulations.



Fitting Box-bodies

Figure 3.18

123840

1. Subframe - 2. Brackets - 3. Plates - 4. Tipping hinge bracket



Fitting Box-bodies

3.4.3 Heavy-duty Service

Not applied to StralisNOTE

3.4.4 Light-duty Service

For these operations we recommend using vehicles with short wheelbases. In Table 3.5 are listed the longitudinal runners tobe used. It is understood that the vehicle must be used for light duty on good roads, to transport freight with a low density anda low coefficient of friction.

In addition to the above general specifications, in order to give the vehicles the required rigidity and stability, the following pointsmust be observed:

- Carefully check the chassis specifications (suspension, chassis, number of axles) to select a vehicle suitable for the body and itsintended operation.

- The rear end of the subframe must be stiffened using box-type sections, crossbraces, cleat plates etc.

- The rear tipping hinge must be placed as near as possible to the rear hanger bracket of the rear suspension.

- In cases of vehicles having wheelbase longer than the standard tipper wheelbase, specially stiffened rear tipping support anchoringshould be used so as to contain sag and ensure good stability during operation.The rear tipping angle should be between 45º while the user should be informed that the tipping should be done on as flat asurface as possible.

- Use the most rigid rear suspension available and rear anti roll bars. When parabolic rear springs are used, the stiffness shouldbe increased using rubber elements that operate at static load.

- For vehicles with pneumatic rear suspension, (for 6x4 tandems with four air springs for each axle), dump the air from the suspen-sion during the tipping operation to allow the vehicle the greatest stability during tipping. It is important that this operation takesplace automatically from the tipping control. The resetting (raising) of the suspension can also be operated by the tipping controlas the body is lowered.

- On vehicles with standard third axle or added third axle (6x2), an antiroll bar may have to be fitted onto the 3rd axle dependingon the type of installed suspension to improve the transverse stability. In addition to the above instructions, hydraulic or mechan-ical stabilisers may have to be installed for operation depending on the tipping support location in relation to the rear axles, tosuspension types and to intended operation. The third axle must never lift when tipping.

Table 3.5

M d l

Minimum subframe section(yield limit of the material used)

Model Section modulus depending on the material yield limit (N/mm2)

240 360

AT-AD190 46

89(2)

AS/AD/AT260/TN 89/110 (1)

AS/AD/AT260/PT260Z/P 150/190 (1)

89/110 (1)

AS/AD/AT260/P(S)FP/FS 173/222 (1)

89/110 (1)

(1) Necessity for a boxed section with connections resistant to shearing, starting from approx. 1000 mm in front of the centreline of the drive axle(s) up to therear end of the chassis.

(2) For 8000 kg. On axle



Fitting Box-bodies

3.4.5 Containers

Not all vehicles lend themselves equally well to be used for removable type containers (i.e. the containers which can be unloadedby sliding along the subframe). Heavy duty vehicles are certainly better suited to this use but it is best to consult IVECO concerningthe suitability of the various models in relation to the use of the vehicle. (Table 3.4)

This type of operation is subject to additional stresses compared to those of normal on-road vehicles with fixed platform bodies,in particular as regards loading/unloading operations.

For this reason, the auxiliary frame used (see point 3.1) should be of the same dimensions as that for light tippers. (point 3.4.4)

Where vehicles with long wheelbases or rear overhangs are used, it may be necessary to use runners of larger dimensions for thesubframe.

The interchangeable body must rest on the vehicle subframe along its entire length or a least be in contact with an extensive areaof the suspension attachment points.

The lifting devices must be fixed to the subframe as indicated in point 3.6.

Vehicle stability must be guaranteed and comply with DIN standard 30722.

The stability of the vehicle must always be ensured during loading and unloading operations. We recommend fitting the rear endswith supports (stabilisers) that are to be used during loading and unloading operations particularly when roll on, roll off containersare used.

These supports are also recommended if the rear axles have pneumatic suspensions.

As an alternative, refer to the explanations in point 3.4.4, concerning dumping the air from the suspension during the operation.

It is very important, with this type of vehicle, to adhere to the specifications concerning the height of the centre of gravity (see point1.13.2), when containers for high payloads are used.

Figure 3.19

123839

The distance between the last rear axle and the sliding pivot must not exceed 900 mm.



Tractors for Semitrailers


3.5 Tractors for Semitrailers

For this use the vehicles provided by Iveco with specially designed equipment (chassis, suspension, brakes) should be used. Themodels with pneumatic rear suspension are particularly well suited because of the constant height of the fifth wheel to transportcontainers.

3.5.1 Position of the Fifth Wheel

The position of the fifth wheel may be selected from among the positions established by Iveco in relation to the kerb weightof the tractor in its standard version. If, as a result of subsequent additions and/or modifications, the kerb weight should be changed,reference must be made to the actual weight of the tractor and its complete equipment (supplies, driver, equipment etc.) in observ-ance of the permissible loads on the axles when checking the position (see point 1.13.1).

To ensure a correct coupling with the semitrailer, particularly when the fifth wheel forward positions differ from the standard ones,the geometric positioning must be carefully checked (see point 3.5.3).

3.5.2 The Fifth Wheel

All fifth wheels having load characteristics, dimensions and performance that have been declared suitable for a specific use bytheir manufacturer, may be used on our vehicles. The type of fifth wheel to be selected depends on the vehicle and on the typeof transport to be carried. For instance, for off-road use, fifth wheels with an adequate degree of transverse oscillation must be usedto avoid excess stress on the vehicle’s chassis due to torsion.

Where government regulations require it, fifth wheels must meet all requirements or be homologated. Regarding their mounting,number of bolts, dimensions, materials and positioning of longitudinal and transverse stops, see the instructions provided by themanufacture of the fifth wheels.

As the fifth wheel is very important to vehicle safety, it must not be modified in any way.

3.5.3 Coupling of Tractor and Semitrailer

Semitrailers must not have constructive characteristics (such as excessively flexible chassis, inadequate braking power) that wouldadversely affect the operation of the tractor. The coupling of the tractor and the semitrailermust take into account all their respectivemovements under all operating conditions and ensure adequate safety margins which may be required by law or regulations forroad use (see Figure 3.20).





Figure 3.20

E=Front tractor clearance space - E1=Front tractor turning radius -F=Rear tractor turning radius - F1 =Rear semitrailer clearance space

When required to do so, the required manoeuvring space in curves must be checked.

Concerning the definition of the height from the level of the 5th wheel, any limits imposed by the Manufacturer and/or governmentregulations must be observed.




3.5.4 Fifth Wheel Mountings

When the tractor is delivered without the bed plate for the fifth wheel, the following instructions must be adhered to for itsconstruction:

- The mounting must be adequately dimensioned to handle the vertical and horizontal loads transmitted by the fifth wheel. Con-cerning its height, bear in mind what has been said in previous points.

- Concerning the properties of the material and mounting, refer to point 3.1.1 and 3.1.2

- The upper and lower surfaces of the mounting must be even to ensure a good bearing on the chassis of the vehicle and of thebase of the fifth wheel.

- In cases where the mounting is supplied in component parts they must be assembled by welding and/or riveting.

- The fixing of the mounting to the chassis (see Figure. 3.21, 3.22 and 3.23) must be made on the angle support, if provided oras otherwise specified.

For the fixing use flanged head bolts and nuts with a min, class of 8.8. An arragement to stop the bolts working loose must beused. The number of bolts and diameter must be at least equal to that require to secure the fifth wheel.

When attaching logitudinal stop this must be achieved without welding or making holes in the sidemember flanges.

It is permissible to attach cad up ramps to the chassis, on marking and fitting them. The following must be considered.

- To make them of suitable size to ensure that the semitrailer can be properly engaged with the fifth wheel.

- That the fixing to the chassis must be achieved without welding or making holes in the side member flanges.

Installation of Simple Plate-type Mounting

As a general rule, for tractors that are intended for normal road use, and if not otherwise specified by Iveco, the mounting platefor the fifth wheel must be fret-shaped (see Figure 3.21), connected to the chassis by means of longitudinal runners and appropriatebrackets.

For certain models and markets this type of installation may also be permitted not exclusively for on-road uses. In these cases, thenature of the use and of the loads does not require direct contribution by the structure to the chassis to counteract the effectsof flexing and torsion.

The fret -shaped plate is supplied with the vehicle and provisionally fastened to it.

The final installation will be carried out by the person in charge of the installation of the fifth wheel.

The fifth wheel support plate is especially important to safety (in some countries it must be specifically certified). Assembly instruc-tions must be strictly followed and no modification carried out.




Table 3.6 - Fifth wheels

Fifth wheel and plate application Tractors 4x2 Tractors 6x2C Tractors 6x4

Fifth wheel mounting plate 440T/P 440T/FP-LT 440TX/P 440TZ/P-HM

Fifth wheel with pin 2’’, H = 140 mmintegrated plate

/ S / /

Fifth wheel with pin 2’’, H = 150 mm - Jost+ plate 50 mm

f / f f

Fifth wheel H = 150 mm+ plate 100 mm

f / f f

Fifth wheel rest plate H = 150 mm+ plate 12 mm

f f / /

Fifth wheel mtg plate H = 100 mm f / f f

Fifth wheel mtg plate H = 50 mm f / f /

Fifth wheel with pin 2’’, H = 185 mm+ plate H = 12 mm

f / f f

Fifth wheel with pin 2’’, H = 185 mm+ plate H = 100 mm

f / f f

Fifth wheel without plate - Jost H = 190 mm f / / /

Fifth wheel without plate - Jost H = 225 mm f / / /

Fifth wheel H = 148 mm

+ plate H = 8 mmf / / /

S standard

f optional




Table 3.7 - Fifth wheel dimensions

Plateheight

Fifth wheelheight

Iveco / Jost fifth wheelheight (without plate)

Fifth wheel height withintegrated plate

(mm) (mm) (mm) (mm)

50 150 200

50 185 235

100 185

12 150 162 Iveco

8 148 140 Jost

Table 3.8 - Model/type application

Total fifth wheelheight

Models Suspensionsetting

Tyres Mudguard Fifth wheel plateheight from the ground

(mm) (mm) Dimension C (*)(mm)

(mm laden)

200 4X2 / P 160 (S) 315 / 80 150 ∼1170

295 / 80 ∼1155

140 (O) 315 / 70 120 ∼1120

(SW 06114) 305 / 70 ∼1110

315 / 60 ∼1090

295 / 60 ∼1075

235 4X2 / P 160 (S) 315 / 80 174 ∼1205

295 / 80 ∼1190

285 4X2 / P 160 (S) 315 / 80 174 ∼1255

295 / 80 ∼1240

162 4X2 / P 140 (O) 315 / 60 120 ∼1050

(SW 06114) 295 / 60 ∼1035

305 / 70 ∼1070

315 / 70 ∼1080

140 4X2 / FP-LT 85 295 / 60 120 ∼960

315 / 60 ∼975

162 4X2 / FP 85 295 / 60 120 ∼985

(156) 315 / 60 ∼1000




Fitting instructions for 4x2 models: AS/AD/AT 440 S... T/P and T/FP

Figure 3.21

1. Fifth wheel centreline - 2. Rear wheel centreline - 3. Fifth wheel position - 4. Longitudinal runners - 5. Fifth wheel bed plate -6. Class 10.9 M16x1.5 screws - 7. Fixing spacers (h=15mm) - 8. Self-locking flanged-head nuts - 9. Chassis side members

A View from A B View from B

Centre linemissing

A B

Bed Plate Fixing

- Having determined the fifth wheel forward position, secure the longitudinal runners to the plate using screws (6), spacers (7)and the self-locking nuts (8).

- Tighten the nuts (8) (tightening torque 260 to 300 Nm).




Fitting instructions for models 4x2: AS/AD/ATD 440 S...T/P and T/FPWith crossbrace (Option 7727 - 7728)

Figure 3.22

1. Fifth wheel centreline - 2. Rear wheel centreline - 3. Fifth wheel position - 4. Longitudinal Runners - 6. Class 10.9 M16x1.5screws with flange - 7. Washer (h=6mm) - 8. Self-locking flanged-head nuts - 9. Chassis side members




Fitting instructions for models 4x2: AS/AD/AT 440 S...T/P and T/FPWithout crossbrace (Option 7830)

1. Fifth wheel centreline - 2. Rear wheel centreline - 3. Fifth wheel position - 4. Longitudinal Runners - 5. Plate -6. Class 10.9 M16x1.5 screws with flange - 7. Washer (h=6mm) - 8. Self-locking flanged-head nuts -

9. Chassis side members - 10. Fixing spacers (h=15mm)

Figure 3.23




3.5.4.1 Preparation and installations of a Structure Working together with Chassis

In addition to distributing the weight that bears on the fifth wheel the purpose of installing a suitable mounting similar in construc-tion to the subframe shown in Figure 3.24, is to give the vehicle’s chassis added torsional and flexional strength. It is required forextreme heavy- duty operations in certain markets for the models indicated in Table 3.9. The table also gives the minimum dimen-sions for the longitudinal runners for the side members. For dimensions, see table 3.2 depending on modulus of resistance Wx.

These must be connected by cross members, an adequate number of which must be placed in the area where the fifth wheel ispositioned, while the remainder are distributed at the end of the straight section.

The mounting plate bearing the fifth wheel may be constructed in one of the following ways:

- by means of a plate of suitable thickness, of a length and width which is proportional to the fifth wheel supports or by meansof two plate halves of greater length;

- by means of a fret-shaped plate which the Manufacturer of the fifth wheel can supply ( height 30 or 40 mm) where there areno problems concerning the height of the fifth wheel.

The plate(s) on which the fifth wheel is fitted must be joined rigidly to the framework of the base (side and cross members).

The supports already provided by Iveco (longitudinal and/or cross members)must be used to secure the structure to the main frame.The best type of connection is provided by the use of plates at the rear and in proximity to the fifth wheel to stop sideways andlengthwise movement, and brackets towards the front (see Figure 3.24). In addition to the other general type specifications givenin point 3.5.4, the specific requirements stipulated for certain models on their respective drawings (are available on request) mustalso be adhered to.

2 Axles min. 21003 Axles min. 1700

2 Axles min. 21003 Axles min. 17002 Axles min. 8003 Axles min. 1000

B

Figure 3.24Solution 1

Solution 2

A.R.A.

1. Fifth wheel pivot centreline - 2. Rear wheel or tandem centreline - 3. Fifth wheel position - 4. Standard equipment anglepiece - 14 dia. screws - 5. Front brackets - 16 dia. screws - 6. Plates - 14 dia. screws - 7. Longitudinal runner (see Table 3.5)Av = Distance between front axle and fifth wheel centreline Lv = Minimum required reinforcement lenght when a LH =

special runner profile (see Table 3.9) is used - 8. Stiffening crossties - 9. Rear cross members (for L> 400 mm) -10. Half-plate (min thickness = 8 mm) - 11. Plate (min. thickness = 10 mm) - 12. Fret-shaped plate - 13. Channel profile -

14. Fixing angle piece

2 axles min. 12003 axles min. 1700

2 axles min. 12003 axles min. 1700




Table 3.9 - Minimum indications of subframe profile

Minimum reinforcement profile

Models Wheelbase(mm)

Section modulus based on theyield point of the material

(N/mm2)( )FE240 = S235

240

FE360 = S355

360

AS/AT/AD 1901)

AS/AT/AD 440 T; T/P: T/FP

3200

≤ 3500

≤ 3800

902)3)

1502)3)

2082)3)

572)5)

572)4)

902)4)

AS/AD/AT 260/Z/P1)3200/1380

1736)

2082)3)426)

1502)5)AS/AD/AT 260/Z/PAS/AD/AT 440 T

3500/13802086)

2082)3)576)

2082)5)

AS /AD/AT 260/P; /PS; /FP; /FS; /FT; /FT1) 3200/1395 2086)736)

2082)5)

AS/AD/AT 260/P; /FP1)

AS/AD/AT 440 TZ/P;2800/1395 2086)

576)

2082)5)

1) When converting a truck into a semitrailer tractor, the wheelbase to be used must be equal to that of standard tractors, or suitably reduced.

2) For heavy-duty use of vehicle (e.g. non-EU countries).

3) For heavy-duty use of vehicle up to 6500 kg on the front axle



6) For on-road use of vehicle and load on front axle ranging from 7500 to 8000 kg (this is obtained by means of high fifth wheel displacement values).

Should it be necessary to reduce the height of the runner profile using shear resistant connections between the chassis and thesubframe (see Table 3.9) instead of the channel profile specified in Figure 3.24, it is possible to make use of combined section runnerprofiles (see table below) provided the width and thickness values are no less than the tabulated ones. These are instructions ofa general nature applying to the material covered by this manual. Materials of higher mechanical specifications call for the measure-ment of the overall chassis and subframe bending moment. Do not use sections with a height of less than 80 mm in order to providethe chassis with adequate stiffness characteristics.

For section dimensions see Table 3.2.




Solutions adopting combined section reinforcement profiles (see Figure 3.3)

A B C o D E F G

Material yield point(N/mm2)

≤ 320 ≤ 320 ≤ 240 ≤ 240 ≤ 360 ≤ 360

Max. runner profile heightreduction (mm)

40 60 100 120 100 120

Combined reinforcementslengthLV:LH:(see Figure 3.23)

0.3AV

0.2AV

0.4AVV

0.22AVV

0.5AV

0.25AV

0.55AV

0.25AV

0.5AV

0.25AV

0.55AV

0.25AVV

Example:Combined section as an alternative tothe channel section (mm):

210X80X8 190X80X8 150x80x8+ straightsection15x80




Actual height reduction(mm)

40 52 85 97 92 104

The above data cannot be used when the subframe is connected to the vehicle chassis by means of brackets. In this case, moments of resistance and stress datamust be calculated for each chassis and subframe section.

3.5.4.2 Converting a Truck into a Semitrailer Tractor

In certain cases, on models where no tractor unit was originally planned, it is possible to obtain the necessary authorisation to converta truck into a semitrailer/tractor. The specifications relative to such a conversion in terms of fifth wheel mountings, modifications of thechassis (i.e. suspension, braking system etc.) based on the use of the vehicle, must be defined in each case.

3.5.4.3 Variable height fifth wheel (only for Low tractor)

Iveco offers its Customers a variable height fifth wheel solution, type-approved only for Low tractor units.

It must be clarified that the above device may be used in the lower position for any type of vehicle (except quarry and building siteand tipper trucks), while in the higher position it must not be permitted under any circumstances for the following applications:

• Conversions with high centre of gravity

• silos

• Tanker trucks

• Tipper trucks

• Quarry and building site vehicles

The maximum height of the fifth wheel measured from the ground surface is also authorised up to 1200 mm in accordance with EECBraking certificate.



Transport of Indivisible Materials (Bascules)

Transport of Indivisible Materials (Bascules)

3.6 Transport of Indivisible Materials (bascules)

The transport of indivisible material and of freight whose dimensions exceed normal ones, is regulated in various countries byspecial legislation.

The particular configuration of these transports in which stress is created as a result of the concentrated vertical load and of thedynamic forces that may arise when braking, requires that the choice of vehicle to be used is checked with Iveco beforehand.

The structure that bears the weight on the tractor must use a subframe (see point 3.5.4.1): other conditions that must be met forthis type of transport will be specified each time in our authorisations.



Installation of Tanks and Containers for Bulk Materials


3.7 Installation of Tanks and Containers for Bulk Materials

a) Installation through application of a subframe

As a general rule, the installation of tanks and containers on our vehicles requires the use of an appropriate subframe.

Table 3.10 contains the recommendations for the dimensions of the longitudinal runners to be used for the subframe.

Table 3.10 - Installation of tanks

Minimum reinforcement profileModels Section modulus Wx (cm3)

(Yield limit of material used=360N/mm2)

AS/AD/AT 190 461)

892)

AS/AD/AT 260 591)

892)

(1) Stiffen the subframe in the area on which the tanks and containers rest;

(2) Locate the front tank support in front or near to the rear support of the spring on the 2nd front axle, otherwise the use of a larger section and specific authorisa-tion will be necessary.

Tankers, or more generally, structures which are torsionally very rigid, must be fitted so that the vehicle chassis retains sufficientand gradual torsional flexibility, by avoiding areas of high stress.When installing a tank we recommend using elastic joints (see Figure 3.25) between the body of the tank and the subframe in frontand rigid supports that are capable of withstanding longitudinal and transverse forces at the rear.

Figure 3.25

As mentioned in the case of other applications, the positioning of the mountings through which the forces are discharged is similarhere. Rigid mounts are position corresponding to the rear suspension supports and the flexible mounts as near as possible to therear support of the front suspension.

When faced with a different situation, a possible solution could be that of reinforcing the structure by means of longitudinal runnerprofiles of larger dimensions in comparison with those given in Table 3.10.




The rigidity characteristics of the vehicle chassis as well as the area where the connections are to be installed and the type of usefor which it is intended must be taken into account.As a rule, for road use, it can be said that the first front elastic connection will allow for a gap of approximately 10 mm betweenthe subframe and frame during the chassis torsional stage.

In order to define the elastic connection.

b) Installation without application of a subframe

Tanks may be mounted directly onto the vehicle chassis without fitting an subframe under the following conditions:

- the distance between saddles must be determined depending on the load to be carried and must not exceed 1 meter.

- saddles must be fitted so as to allow an even distribution of the loads over a considerably large surface. Suitable brackets mustbe provided between the saddles to limit the longitudinal and transverse thrusts.

- other anchoring solutions may be authorised by Iveco.

- self-bearing tanks may be positioned directly on the chassis by means of suitable mountings located right behind the cab andin the area of the rear axle(s). The number and distribution depends on the number of axles and the wheelbase; this may varyfrom min. 2 for each side on 2- axle vehicles with short wheelbases to min. 3 for 3/4-axle vehicles with short wheelbases (seeFigure 3.26).

- the mountings must be sufficiently long (600 mm approx) and be positioned next to the suspension mountings (max. distance400 mm).

- to permit the necessary torsional movements of the chassis, elastic front mounting should be used where possible.

Other solutions are possible depending on the type of construction.




Figure 3.26

The installation of two or more separate containers or tanks on the vehicle requires the use of subframe that permits good distribu-tion of the load and an adequate torsional rigidity for the chassis/subframe using connections resistant to shearing. A good solutionis constituted by using a rigid connection which connects the containers together.

In order to adhere to the maximum admissible load limits on the axles, it is necessary to establish the maximum volume, the degreeof filling of the container and the density of the freight. When separate tanks or individual containers with separate compartmentsare used, care must be taken to ensure that with every degree of filling the maximum permissible load on the axles is respectedas well as the minimum ratio between the load on the front axle and fully loaded vehicle weight (see point 1.13.2).

In consideration of the nature of this equipment, special attention must be paid to limiting the height of the centre of gravity as muchas possible to ensure good handling (see point point 1.13.2); we recommend the use of vehicles with stabiliser bars.

It is necessary to provide special transverse and longitudinal bulkheads inside the tanks and containers for liquids in order to reducethe dynamic loads which the liquid transmits when the vehicle is in motion and the tanks are not filled to capacity which wouldadversely affect the handling and resistance of the vehicle.

The same holds true for trailers and semitrailers, in order to avoid dynamic loading on the coupling devices.

Concerning the installation of containers for fuel or flammable liquids, all current government safety regulations must be abided by(see point 2.18).



Installing a crane

Installing a crane

3.8 Installing a crane

The selection of the crane must be made with due consideration to its characteristics (weight, maximum torque) in relation tothe performance of the vehicle.

The positioning of the crane and of the payload must be done within the load limits permitted for the vehicle. Installation of thecrane must be carried out in compliance with statutory requirements, national standards (e.g. CUNA, DIN) and international stan-dards (e.g. ISO, CEN), depending on which of these is pertinent to the particular vehicle.

While the crane is operating, the stabilisers (hydraulic if possible) must be used and be in contact with the ground. As a general rule,the installation of a crane requires the use of a suitable subframe, whose construction must taken into account all general specifica-tions relating to it (point 3.1). Concerning the dimensions of the runners for the subframe, refer to Tables 3.12, 3.13 and 3.14.

In those cases where no specific subframe is called for (areas indicated with an ”A”) it is still necessary to provide a suitable mountingon the chassis for the crane using the standard body subframe (the length of the section members must be at least 2.5 times thewidth of the base structure of the crane) in order to distribute the load and the stress developed during the operation of the crane.

If the vehicle requires the use of its own subframe, it may also be used for the crane provided that its dimensions are adequate.

Special cases, whose Mg value fall within the areas designated with the letter ”E” (or for higher values) must be checked individuallyeach time.

MG max = (F · L + P · l) max

Figure 3.27

The dimensions of the subframe refer to the total maximum static moment of the crane (MG max.) which is calculated on thebasis of the equation given in Figure 3.27.

The decision concerning the number of stabilisers and the type of subframe to be used, particularly in terms of torsional rigidity (box-type sections, cross members etc.) is determined by the maximummoment of the crane and its position for which the Manufacturerof the crane and installer are responsible.

The verification of the stability of the vehicle when the crane is operatingmust be done in compliancewith the applicable governmentregulations.



Installing a crane

3.8.1 Crane Behind the Driver’s Cab

The mounting of the subframe onto the chassis will as a rule, be made using the standard brackets (see Figure 3.28) to whichare added, if necessary, other flexible anchorages (brackets or clamps) so that the flexibility and torsional characteristics of the chassisremain unchanged.

The dimensions and the subframe to be used for this type of installation are specified in Table 3.9.

For on-road vehicles only if the height of the subframe runner profile has to be reduced (e.g. to lower the total height of the vehicle)the mounting of the subframe may be carried out with shear resisting connections (see Figure 3.29). For these applications, theminimum dimensions of the reinforcing runner are specified in Table 3.10. In all case the maximun rear wheel travel / movementmust be allowed.

The use of runners with a constant cross-section is recommended over the entire useful length of the vehicle. Any possible gradualreduction of the cross-section of the runners is permissible in those areas in which the flexional moment induced by the crane as-sumes values that correspond for those of boxes marked ”A”in Tables 3.12. and 3.13.

The subframe for the crane may be integrated with the body longitudinal runner as shown in Figure 3.28 Length ”Lv” must not beless than 35% of the wheelbase for vehicles with forward-control cab when the body runner has a smaller cross-section.

Figure 3.28

1. Subframe - 2. Connections - 3. Crane joints - 4. Stabilisers



Installing a crane

Table 3.11 - Cranes mounted behind the driver’s cab (subframe mounted with brackets or clamps)

Models Wheelbase (mm) Crane capacity MG max (kNm)

Yield 20 30 40 50 60 70 80 90 100 120 140 160 180 200 220 240 260 280

point of

bf- - - - - - - - - - - - - - - - - -

(Chassis frame

subframe

material20 30 40 50 60 70 80 90 100 120 140 160 180 200 220 240 260 280 300

(Chassis frame

section in mm)

material

(N/mm2) Minimum value of subframe Section Modulus Wx (cm3)

AS 190

AS 260

(289X80X6,7)

240

360

420

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

211)

211)

211)

89

89

89

343

119

119

439

150

150

E

245

185

E

374

208

E

439

245

E

E

343

E

E

406

AS 260 Y/P

AS 260 Z/P

(289X80X7,7)

5700/1395

6050/1395

240

360

420

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

211)

211)

211)

89

89

89

406

119

119

E

150

150

E

245

185

E

374

208

E

474

245

E

E

343

A = The reinforcing profile prescribed for the respective superstructure is sufficient (e.g. for normal bodies). Close the reinforcing profile in the crane mountingarea. In the crane area, reinforcing profiles with thickness of less than 5 mm must be reinforced.

E = To be checked on a case-by-case basis. Send the technical documentation with the checks of stresses and stability to the appropriate IVECO bodies.

(1) When the auxiliary frame requires a high moment of resistance (e.g to install platforms) the latter shall be established also for the crane.

Figure 3.29

When installing cranes on large-cab vehicles, should it be impossible to extend the subframe up to the rear support of the frontspring, it may be necessary to contain crane rotation according to crane capacity, so as not to exceed bending moment allowancefor the chassis.



Installing a crane

Installation of cranes on off-road vehicles may require fitting elastic mountings between the chassis frame and subframe on the frontand central areas (see Figure 3.11) so as not to excessively constrain the chassis torsional movement. Since in such cases the cranewill be virtually connected to the subframe only, the size of the longitudinal runners must be adequate to resist the crane operation-generated movements.

The functioning of the equipment that is placed behind the cab (e.g. gear levers, air filter, locking device for the tilting cab etc.) mustnot be impaired. Relocating assemblies such as batteries box or fuel tank is permissible provided that the original type of connectionsare re-established.

Normally, when the crane is placed behind the cab, it is necessary to move the body or equipment towards the rear. In the specificcase of tipping equipment, particular care must be given to the placement of the lifting device and of the rear tipping hinges whichshould be moved back as little as possible.

Table 3.12 - Cranes mounted behind cab (subframe fixing with shear-resistant plates)


Yieldpoint of

20 30 40 50 60 70 80 90 100 120 140 160 180 200 220 240 260 280point ofsubframe

i l- - - - - - - - - - - - - - - - - -

(Ch i f

sub a ematerial(N/mm2) 20 30 40 50 60 70 80 90 100 120 140 160 180 200 220 240 260 280 300

(Chassis framesection in mm)

(N/mm )

Minimum value of subframe Section Modulus Wx (cm3)1)

AS 190

AS 260

(289X80X6,7)

up to 6300

up to 5100/1395

240

360

420

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

311)

A

A

46

A

A

89

311)

A

105

46

31

150

89

361)

173

89

89

245

135

89

E

150

105

173

135

208

150

245

173

AS 260 Y/P

AS 260 Z/P

(289X80X7,7)

5700/1395

6050/1395

240

360

420

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

311)

A

A

361)

A

A

89

311)

A

89

361)

A

135

89

311)

150

89

46

208

105

89

245

135

89

E

150

105

173

135

Section modulus Wx (cm3)required for the chassis +subframe aggregate section

240

360

420

490} *

63

48

40

34

94

72

60

50

125

96

80

67

157

120

100

84

188

143

120

100

219

167

140

117

250

191

160

134

282

215

180

150

313

238

200

167

375

286

240

200

438

334

280

234

500

381

320

267

563

329

360

300

625

477

400

334

688

524

440

367

750

572

480

400

813

169

520

434

875

667

560

467

938

715

600

500

* Also valid for chassis runner profile (lower flange of the aggregate section).

A = The reinforcing runner required for the corresponding subframe is sufficient (e.g. Table 3.4 for standard platform bodies).

The reinforcing runner in the crane’s mounting area is to be closed. In the same area, the reinforcing runners with thickness less than 5 mm are to be reinforced.

E = To be checked for case to case (submit the technical documentation with the calculation made to determine stress and stability).

(1) When the auxiliary frame requires a high moment of resistance (e.g to install platforms as per Table 3.1) the latter must be established also for the crane.

2) The application of these capacity ranges of the cranes requires that the vehicle’s stability be carefully verified (possibility of using stabilisers with a greaterextension or resorting to heavier ballast).

3) Should one wish to reduce the height of the runner profile using shear resistant connections between the chassis and subframe instead of the specified channelsection (moment of resistance as per Table 3.12) it is possible to make use of combined section runner profiles (see table below) provided that the flangewidth and thickness values are no less than the tabulated ones. These are instructions of a general nature appl ying tomaterials covered by this manual.Materialwith higher mechanical specifications call for the measurement of the overall chassis and subframe bending moment (see last part of Table 3.13). Howeverit should be remembered that for the part of the runner profile which is not reinforced (channel section) the moment of resistance must not be less thanthe one required for the subframe concerned (i.e. Table 3.4 for fixed platform bodies).As a reduction of the subframe runner entails a reduction in the subframe moment of resistance, the Bodybuilder who is envisaging the installation of a cranewith 4 stabilisers will have to work out the means for ensuring adequate torsional stiffness for the af in the crane resting area. For this reason we recommendthat the height of the runner profiles be not less than 120 mm. However, as this solution also implies a restriction of the torsional capacity of the main chassiswhile the vehicle is travelling, we recommend that its use be confined to on-road use



Installing a crane

Installing a crane

Table 3.13 - Solutions with combined section runner profiles (see Figure 3.5)

A B C o D E F G

Material yield point(N/mm2):

≤ 320 ≤ 320 ≤ 240 ≤ 240 ≤ 360 ≤ 360

Max. runner profile heightreduction (mm):

40 60 100 120 100 120

Combined reinforcementslength(see Figure 3.26) LV= 0.25Lh or

LA 0.35Lhor LA 0.4Lh or

LA 0.45Lhor

LA 0.55Lhor

LA 0.6Lh or.LA

Example:Combined section as an alternativeto the channel section (mm):C250x80x8 mm:

210x80x8 90x80x8 150x80x8+ straightsection15x80




Actual heightreduction (mm)

40 52 85 97 92 104

The above data cannot be used when the subframe is connected to the vehicle chassis by means of brackets (see Table 3.11). In this case, moments of resistanceand stress data must be calculated for each chassis and subframe section.

3.8.2 Crane on Rear Overhang

It is advisable for this type of application, to extend the subframe over the entire length of the vehicle that is available for thebody up to the back of the cab or if this is no possible the rear support of the front spring. The dimensions of the runners to beused are given in Table 3.14.

In consideration of the particular distribution of the load on the vehicle, where the load is concentrated on the rear overhang, inorder to ensure the rigidity that is necessary for good performance on the road and when the crane is in operation, the subframemust be strengthened and stiffened in relation to the capacity of the crane. Box-type sections (see point 3.2) and brackets are tobe used in the area of the rear suspension and the rear overhang (Length Lv as per Figure 3.30). Care must also be taken to ensurethat the transition from box-type to open section is well blended as illustrated in Figure 3.5 and 3.6.

In the area that is affected by the box-type section, the framemust be secured to the chassis of the vehicle bymeans of shear-resistantplates (i.e. an adequate number of plates spaced at most 700 mm from each other), whereas elastic mountings are to be used inthe front part. Due care must be taken to ensure that under any load conditions, the ratio of the weight on the front axle to therear axle or axles, respects the limits set for the vehicle (see point 1.13.3).

As the required stiffness of the subframe depends on various factors (i.e. crane capacity, size of its supporting base, vehicle kerbweight, chassis overhang) we cannot give information valid for all possible conditions. For this reason the bodybuilder will have toassess the vehicle stability also by means of practical tests. If, as a consequence of such tests , the subframe stiffness proves insufficient,the bodybuilder will have to achieve this objective by means of alternative methods.

The rear overhang of the crane (length Lu, see Figure 3.30) must be limited as much as possible in order to preserve the good drivingcharacteristics of the vehicle and acceptable stress conditions. This value must not exceed 50% of the wheelbase.

In the case of vehicles with a lifting rear axle, the verification of the minimum load on the front axle must be done with the rearaxle in the raised position in those countries which permit driving under those conditions (see point 1.13.3). If the minimum pre-scribed value is not reached, the vehicle must be allowed to drive only with the axle in the lowered position.



Installing a crane

Figure 3.30

1. Subframe - 2. Plates - 3. Brackets - 4. Crane joints - 5. Stabilisers - 6. Connecting angle bar

Lv

Table 3.14 - Cranes mounted on rear overhang (subframe mounting with shear resistant plates)


Yieldpoint of

20 30 40 50 60 70 80 90 100 120 140 160 180 200 220 240 260 280point ofsubframe

i l- - - - - - - - - - - - - - - - - -

(Ch i f

sub a ematerial(N/mm2) 20 30 40 50 60 70 80 90 100 120 140 160 180 200 220 240 260 280 300

(Chassis framesection in mm)

(N/mm )

Minimum value of subframe Section Modulus Wx (cm3)1)

AS 190/PAS 260/P; /PS;/FP; /FSAS 260/PT(289x80x6,7)

up to 6300up to 5100/1395up to 5100/1395up to 5100/1395up to 5100/1395

240360420

AAA

AAA

AAA

AAA

AAA

231)

AA

321)

AA

421)

231)

231)

57321)

231)

110421)

321)

13571421)

17311071

222135110

246173135

E222173

222173

246222

E246 E

AS 260 Y/PAS 260 Z/P

(289X80X7,7)

5700/1395up to 5700/1380up to 6050/1395up to 6050/1380

240360420

AAA

AAA

AAA

AAA

AAA

AAA

AAA

AAA

AAA

AAA

422323

713223

1104223

1355742

17311057

22211071

222135110

E135135

173173

Section modulusWx (cm3) requiredfor the chassis + subframecombinedsection

240360420490 } *

63484034

94726050

125968067

15712010084

188143120100

219167140117

250191160134

282215180150

313238200167

375286240200

438334280234

500381320267

563329360300

625477400334

688524440367

750572480400

813169520434

875667560467

938715600500

* Also valid for chassis runner profile (lower flange of the combined section).


The reinforcing runner in the crane’smounting area is to be closed. In the same area, the reinforcing runners with thickness less than 5mmare to be reinforced.


I = When the auxiliary frame requires a high moment of resistance (e.g to install platforms as per Table 3.1) the latter shall be used also for the crane.

2 = Should one wish to reduce the height of the runner profile using shear resistant connections between the chassis and subframe instead of the specified channelsection (moment of resistance as per Table 3.14) it is possible to make use of combined section runner profiles (see table below) provided the flange widthand thickness values are no less than the tabulated ones. These are instructions of a general nature applying tomaterials covered by this manual. Material withhighermechanical specifications call for the measurement of the overall chassis and subframe bendingmoment (see last part of Table 3.14). However it shouldbe remembered that for the part of the runner profile which is not reinforced (channel section) the moment of resistance must not be less than the onerequired for the subframe concerned (i.e. Table 3.1 for fixed platform bodies). As a reduction of the subframe runner entails a reduction in the subframemoment of resistance, we recommend that the height of the runner profiles be no less than 120 mm.



Installing a crane

Table 3.15 - Solutions with combined section runner profiles (see Figure 3.4)

B D G

Material yield point (N/mm2) 320 240 ≤ 360

Max. runner profile height reduction (mm): 20 60 80

Combined reinforcements length (see Figure 3.31) LV = - 0.45 LG 0.65 LG

Example:Combined section as an alternative to the channelsection (mm) : 220 x 80 x 8 mm

200x80x8 160x80x8+ straightsection15x80


Actual height reduction (mm) 12 45 64The continuity of combined reinforcement runners can be interrupted only in special cases and is subject to authorisation. Similarly, when it is difficult to applyan external reinforcing L section (items F and G Figure 3.4) - owing to the presence of suspension mountings or air spring connection brackets - and recessingto be performed could excessively reduce the section’s resisting capacity, the adopted solution will need special authorisation.

3.8.3 Removable Cranes

The installation of removable cranes on the rear overhang may be carried out according to the specifications of the precedingparagraph provided the type of fixing used between the crane and the subframe does not cause additional stress to the vehicle’schassis.

In consideration that the vehicle may be used with or without the crane, we recommend marking on the body the position of theuseful load consistent for the two types of operating condition.

If the vehicle retains its ability to tow a trailer, all regulation concerning the proper coupling of the vehicle must be observed.



Installation of Tail Lifts


3.9 Installation of Tail Lifts

The dimensions of the longitudinal runners to be used when installing tail lifts can be assessed as follows:- By means of Table 3.16, with the standard rear overhangs and mean bending moments induced by tail lifts; as a function of theircapacity. In the table, the minimum capacity values are specified above which suitable stabilisers must be used.

- When cantilever tail lifts or with different lengths of the rear overhang and with special tail lifts (e.g. aluminium), the flexural momentsinduced on the chassis frame can be determined by means of Figure 3.31, whereas the characteristics of the longitudinal runners canbe defined using the relevant figure.

The bodybuilder or the Manufacturer of the tail lift must take care to ascertain safety and operational stability, in particular whenapplying Table 3.17.In any event, particularly in those specific uses where there is not a suitable subframe (as in the case with box- type bodies builtby means of cross members), the fixing for the tail lift must be provided by a structure that enablesThe stress to be distributed over the chassis of the vehicle.Fixing with Shear Resisting Plates (ALL TAIL LIFT INSTALLATIONS)To provide the necessary strength and rigidity at the rear of the chassis, the connection between the chassis and the subframemust(especially in overhangs of over 1500 mm) be made using shear resisting plates. These must be fitted in the area of the overhangand of the rear suspension and spaced not more than 700 mm from one another as shown in Figure 3.31.Procedure for calculating the frame bending moment during loading of a tail lift.

Figure 3.31

91538

WtlWI

Combined sectionsolution(see Figure 3.5)

Stabilizers

Rear axle(s) centreline

WTL = weight of tail liftWL = tail lift capacity

The bending moment of the frame can be calculated using the following formula:For tail lifts without stabilisers M [Nm] = WL x A + WTL x BFor tail lifts with stabilisers M [Nm] = WL x C + WTL x D

C, D, WTL, WL : According to tail lift manufacturer’s data.NOTE




The bodybuilder must consider each time the necessity of using stabilisers even in those cases where merely in terms of stressof the chassis their use may not appear to be necessary. When evaluating the need for stabilisers in relation to the capacity of theplatform, the stability and attitude of the vehicle resulting from the deflection of the suspension during loading operations must alsobe considered.

The stabilisers, that must be attached to the platform’s supporting structure, should preferably be hydraulically operated and mustbe employed during all loading procedures with the platform.

The stability of the vehicle must be verified in observance of government regulations in all operating phases of the platform.

To compensate for the elastic give of the chassis, which is inevitable when the tail lift is in operation, the bodybuilder may makeuse of reinforcement runner profiles of larger size in comparison to the one indicated in Table 3.16 and 3.17.

The runner profile dimensions given in Table 3.16 apply to the rear overhangs shown. Should the latter be of larger size, it may benecessary to consider the possibility of either installing stabilisers or larger runner profiles (see Table 3.17).

The installation of tail lifts must be carried out with due regard for the maximum permissible weights on the rear axle or axles andof the minimum load established for the front axle (see point 1.13.3); if this should not be the case, the rear overhang will have tobe reduced.

When electro-hydraulic tail lifts are installed, it is necessary to check that the capacity of the batteries and of the alternator is adequate(see point 5.5).

Vehicles with liftable third axles, the use of a tail lift when the third axle is lifted is only allowed using stabilisers.

The bodybuilder will be responsible for any modification to the rear underrun guard or for installing a different type (see point 2.20)for preserving the visibility of the rear lights, for the overhang angles, and for the positioning of the tow hook as provided by therespective national requirements.




Table 3.16 - Installation of tail lifts

Models Tail lift capacity kN (kg)

Wheelb

ase

Max. bodyoverhang(mm)

7.5(750)

10(1000)

12.5(1250)

15(1500)

17.5(1750)

20(2000)

25(2500)

30(3000)

ase (mm)Minimum value of subframe Section Modulus Wx (cm3) as a function of

2(Chassis frame

Minimum value of subframe Section Modulus Wx (cm ) as a function ofthe yield point of the material (N/mm2)

(Chassis framesection in mm) (mm) 240 360 240 360 240 360 240 360 240 360 240 360 240 360 240 360

AS 190/P 38004200

18472072

22752500

AA

AA

AA

AA

AA

AA

A57

AA

5789

A46

89105

4657

89135

4689

135150

8989

AS/AD/AT 260/P; /PS;/PT(302,4/212,4x80x6,7)

38004200450048005100

-----

22072567252225222252

8989898989

4646464646

8910510510589

4657575746

8913513513589

4689898946

135150150150135

8989898989

135150150150135

8989898989

135173173173135

8910510510589

150208208208150

119135135135119

208286286286208

135150150150135

AS/AD/AT 260/TNAS/AD/AT 260/PT(P. 5700/1380)(302,4x80x6,7)

bis 5700bis 5100

- 3475 A A A A A A A A A A A A A A A A

AS/AD/AT 260/P; /FP;(302,4/212,4x80x6,7)

44714471510151015101510156865686627162716271

13071802157719822207238719822207202723872792

17602250203024302660284024302660248028403240

AAAAAAAAAA89

AAAAAAAAAA461)

AAAAA57AAA571)

89

AAAAAAAAAA461)

AAAA5789A57A89105

AAAAA46AAA461)

571)

AAA5789895789571)

89135

AAAA4646A46A461)

89

A57A8989105898989105135

AAA4646574646461)

571)

89

A89A89891358910589135150

A46A4646894657461)

8989

A8989105135150105135135150208

A464657898957898989135

8913589135150173135150150208245

4689468989105898989105150

AS/AD/AT 260/P; /FP;/FS; /PS(302,4/212,4x80x6,7)

42014201447144714786478647865101

11271622121716221487171220721802

15802070167020701940216025202250

A57A57A898989

AAAAA464646

A89A89578910589

A46A46A465746

A89A898989135105

A46A4646468957

4689578989105150135

A46A4646578989

891058910589135150135

4689468946898989

8913589135105135173150

46894689898910589

105150105150150173207173

5789578989105135105

135208135208173208286208

8913589135105135150135

AS/AD/AT 260/P; /FP

(304,4 X 80 X 7,7)

56866050

- 24322660

AA

AA

AA

AA

A46

AA

A46

AA

4646

AA

4646

AA

4646

4646

4673

4646

AS/AD/AT260 Z/P-HM

(304,4 x 80 x 7,7)

3796379642014201420142014471

1127148711271487162218471982

1580194015801940207023002430

AAAAAAA

AAAAAAA

AAAAAAA

AAAAAAA

AAAAAAA

AAAAAAA

AAAAAAA

AAAAAAA

AAAAAAA

AAAAAAA

AAAAAAA

AAAAAAA

AAAAA4689

AAAAAAA

AAAAA8989

AAAAAA46

For the tail lifts with capacity up to 5 kN (500 kg) the reinforcing runner profile provided for the corresponding subframe is sufficient (e.g. Table 3.4 for standardplatform bodies).

Formodes AS 190 S../P with 2792 mm rear overhang andmodels AS 260 S../P with 1802 and 2072 mm rear overhang, with 5 kN (500kg) tail lifts use the reinforcingrunner profiles provided for the corresponding subframe (e.g. Table 3.4 for standard bodies).




Table 3.17 - Installation of tail liftsBending moment permitted for runner of chassis frame/subframe

Models Moment of resistance Wx (cm3) of subframe runner 2)

Subframe 16 19 21 26 31 36 46 57 89 105 119

Wheelbase

Subframematerial

16 19 21 26 31 36 46 57 89 105 119

Chassis framesection (mm)

Wheelbase(mm)

materialyield point(N/mm2)

Static bending moment permitted or chassis frame/subframe runner(shear resistant connections) (kNm)

(212.4x80x6.7 rear) up to 6300

up to 5100/1395

240

360

420

55.2

72.5

86.3

61.3

80.5

(95.9)

65.6

86.1

(102.5)

63.3

83.1

(99.0)

67.6

88.7

(105.6)

74.7

(98.1)

(116.8)

78.4

(102.8)

(122.4)

82.7

(108.6)

(129.2)

(102.6)

(134.7)

(160.3)

(109.2)

(143.4)

(170.7)

(110.7)

(145.2)

(172.9)

AS/AD/AT 260

(289x80x6.7)

up to 5700/1395

up to 6050/1395

240

360

420

AS/AD/AT 260 (6X4)

(289x80x7.7)

up to 4500/1395 240

360

420

90.7

(119.0)

(141.7)

99.6

(130.7)

(155.6)

(105.7)

(138.7)

(165.1)

(101.4)

(133.1)

(158.5)

(107.5)

(141.0)

(167.9)

(117.8)

(154.6)

(184,1)

(121.5)

(159.4)

(189.8)

(125.9)

(163.3)

(196.8)

(151.7)

(199.1)

(237.0)

(158.0)

(208.2)

(247.8)

(157.8)

(207.1)

(246.5)

Models Moment of resistance Wx (cm3) of subframe runner 2)

Subframe 135 150 173 208 245 286 317 343 374 406 439 474Subframematerial yield

135 150 173 208 245 286 317 343 374 406 439 474

Chassis framesection (mm)

Wheelbase(mm)

material yieldpoint

(N/mm2)Static bending moment permitted or chassis frame/subframe runner

(shear resistant connections) (kNm)

AS/AD/AT 190

AS/AD/AT 260

(199x80x6,7 rear)

up to 6300

up to 5100/1395

240

360

420

(122.8)

(161.2)

(191.9)

(134.1)

(176.0)

(209.6)

(143.1)

(187.7)

(223.6)

(157.7)

(207.0)

(246.4)

(173.0)

(227.1)

(270.3)

(189.7)

(249.0)

(296.5)

(201.6)

(264.6)

(315.0)

(213.9)

(280.0)

(334.3)

(226.8)

(297.7)

(354.4)

(240.1)

(315.2)

(375.2)

(253.9)

(333.2)

(396.7)

(268.1)

(351.9)

(418.9)

AS/AD/AT 260

(289x80x6.7)

up to 5700/1395

up to 6050/1395

240

360

420

AS/AD/AT 260 (6x4)

(289x80x7.7)

up to 4500/1395 240

360

420

(174.3)

(228.8)

(272.4)

(189.9)

(249.2)

(296.7)

(199.3)

(216.6)

(311.4)

(214.5)

(281.6)

(335.2)

(233.3)

(306.2)

(364.5)

(250.5)

(328.9)

(391.5)

(262.8)

(345.0)

(410.7)

(275.7)

(361.8)

(430.8)

(289.0)

(379.3)

(451.6)

(302.9)

(397.5)

(473.3)

(317.2)

(416.4)

(495.7)

(332.1)

(435.9)

(518.9)

( ) The necessity of installing stabilisers and checking stability during operation is to be ascertained.


S = Stabilisers must be installed


C = Normal (short) cab

L = Long cab

I = If the type of subframe requires it, use larger runner profiles (see Table 3.4)

2 = Should one wish to reduce the height of the runner profile using shear resistant connections between the chassis and subframe instead of the specified channelsection (Section Modulus as per Table 3.16) it is possible to make use of combined section runner profiles (see table below) provided the flange width andthickness values are no less than the tabulated ones. These are instructions of a general nature applying to materials covered by this manual. Material withhigher mechanical specifications call for the measurement of the overall chassis and subframe bending moment. However it should be remembered that forthe part of the runner profile which is not reinforced (channel section) the moment of resistance must not be less than the one required for the subframeconcerned (i.e. Table 3.4 for fixed platform bodies). In all case the maximum rear wheel travel / movement must be allowed.




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